Page 750 of 969
F40911
SST
C83179
Wire Cylinder End
Stopper
F40542
SST
51-28
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2603 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. REMOVE POWER STEERING CONTROL VALVE
UPPER OIL SEAL
(a) Using SST and a press, remove the control valve upper
bearing and power steering control valve upper oil seal
from the control valve housing.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00250)
33. REMOVE CYLINDER END STOPPER
(a) Using a screwdriver and a hammer, turn the cylinder end
stopper clockwise until the wire end is visible through the
service hole.
(b) Using a screwdriver and a hammer, turn the cylinder end
stopper counterclockwise, and remove the wire and cylin-
der end stopper.
34. REMOVE POWER STEERING RACK
(a) Remove the power steering rack and power steering rack bush.
35. REMOVE POWER STEERING RACK BUSH
(a) Remove the power steering rack bush from the power
steering rack.
(b) Using SST, remove the rack bush oil seal.
SST 09527-2101 1, 09612-24014 (09613-22011)
(c) Using a screwdriver, remove the O-ring from the power
steering rack bush.
Page 751 of 969
ZX9355
F40544
SST
R10955
C03629
N00401
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-29
2604 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
36. INSPECT POWER STEERING RACK
(a) Using a dial indicator, check the power steering rack for
runout and for teeth wear and damage.
Maximum runout: 0.3 mm (0.012 in.)
(b) Check the back surface for wear and damage.
37. REMOVE POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Using SST and a press, remove the power steering cylin-
der tube oil seal.
SST 09950- 70010 (09951- 07360), 09950- 60010
(09951-00290)
38. REMOVE RACK STEERING PISTON RING
(a) Using a screwdriver, remove the rack steering piston ring
and O-ring.
NOTICE:
Be careful not to damage the grooves for rack steering pis-
ton ring.
39. INSTALL RACK STEERING PISTON RING
(a) Coat a new O-ring with power steering fluid and install it
to the power steering rack.
(b) Expand a new rack steering piston ring with your fingers.
NOTICE:
Be careful not to over expand the rack steering piston ring.
(c) Coat the new rack steering piston ring with power steering
fluid.
(d) Install the rack steering piston ring to the power steering
rack, and settle it down with your fingers.
Page 752 of 969
F40545
SST
SST
W02101
Rack Teeth End
SST
F40543
SST 51-30
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2605 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. INSTALL POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Coat a new power steering cylinder tube oil seal lip with
power steering fluid.
SST 09950- 60010 (09951- 00420, 09951- 00250,
09952-06010), 09950-70010 (09951-07360)
(b) Using SST and a press, install the power steering cylinder
tube oil seal.
NOTICE:
Make sure that the power steering cylinder tube oil
seal is installed facing in the correct direction.
Take care so that the power steering cylinder tube oil
seal will not be reversed as you install it.
41. INSTALL POWER STEERING RACK
(a) Install SST to the power steering rack.
SST 09631-33010
HINT:
If necessary, scrape the burrs off the power steering rack teeth
end and burnish.
(b) Coat the SST with power steering fluid.
(c) Install the power steering rack into the rack housing.
(d) Remove the SST.
42. INSTALL POWER STEERING RACK BUSH
(a) Using SST and a press, install the rack bush oil seal to the
power steering rack bush.
SST 09950- 60010 (09951- 00400), 09950- 70010
(09951-07100)
NOTICE:
Make sure that the rack bush oil seal is installed facing in
the correct direction.
(b) Coat a new O-ring with power steering fluid and install it
to the power steering rack bush.
Page 753 of 969
F05730
Vinyl Tape
Power
Steering
Bush
F40546
Cylinder
End Stopper
Wire
F41507
SST
F40912
SST
SST
F40913
SST
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-31
2606 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) To prevent rack bush oil seal lip damage, wind vinyl tape
around the power steering rack end, and apply power
steering fluid.
(d) Install the power steering rack bush to the power steering
rack.
43. INSTALL CYLINDER END STOPPER
(a) Align the installation hole for the wire of the cylinder end
stopper with the slot of the rack housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using a screwdriver, turn the cylinder end stopper clock-
wise by 450 50.
44. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071 (09633-00010)
(b) Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is a change in the vacuum, check the installation of the
oil seals.
45. I N S TA L L P O W E R S T E E R I N G C O N T R O L VA LV E
UPPER OIL SEAL
(a) Coat a control valve upper bearing and a new power
steering control valve upper oil seal with power steering
fluid.
(b) Using SST and a press, install the power steering control
valve upper oil seal.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00180, 09952-06010, 09951-00320)
(c) Using SST and a press, install the control valve upper
bearing.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00180, 09952-06010, 09951-00340)
Page 754 of 969
C03629
R11573
SST
Valve Ring
F41508
Vinyl Tape
F41509
SST
F41512
51-32
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2607 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
46. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.
NOTICE:
Be careful not to over expand the control valve ring.
(b) Coat the 4 control valve rings with power steering fluid.
(c) Install the 4 control valve rings to the control valve, and
settle them down with your fingers.
(d) Carefully slide the tapered end of SST over the control
valve rings until they fit to the control valve.
SST 09631-20081
NOTICE:
Be careful not to damage the control valve rings.
(e) To prevent power steering control valve upper oil seal lip
damage, wind vinyl tape around the serrated part of the
control valve.
(f) Coat the power steering control valve upper oil seal lip
with power steering fluid.
(g) Install the control valve to the control valve housing.
NOTICE:
Be careful not to damage the control valve ring and power
steering control valve upper oil seal lip.
(h) Coat a new oil seal lip with power steering fluid.
(i) Using SST and a press, install the oil seal.
SST 09612-2201 1
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
(j) Apply grease to the needle bearing.
(k) Install a new gasket to the control valve housing.
(l) Wind vinyl tape around the serration part of the control
valve.
(m) Install the control valve housing to the rack housing with
the 2 bolts.
Torque: 21 NVm (214 kgfVcm, 15 ftVlbf)
Page 755 of 969
F41513
SST
F41502
F41608
F41514SST
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-33
2608 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(n) Using SST, stop the control valve rotation and install a
new lock nut.
Torque: 24.5 NVm (250 kgfVcm, 18 ftVlbf)
SST 09616-0001 1
(o) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(p) Using a socket wrench (27 mm), install the rack housing
cap.
Torque: 58.5 NVm (597 kgfVcm, 43 ftVlbf)
(q) Using a punch and a hammer, stake the rack housing cap
and rack housing.
47. INSTALL RACK GUIDE
(a) Apply molybdenum disulfide lithium base grease to the rack guide.
(b) Install the rack guide.
(c) Install the compression spring.
(d) Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(e) Temporarily install the rack guide spring cap.
48. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH steering rack
ends sub-assy.
(b) Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
Page 756 of 969
F41515SST
F41516
SST
F41517
SST
SST
Rack Guide
Spring Cap
F41518SSTFulcrum Length Rack Guide Spring
Cap Nut
SST
51-34
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2609 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using SST, loosen the rack guide spring cap.
SST 09631-10021
(d) Using SST, turn the control valve to the right and left 1 or
2 times.
SST 09616-0001 1
(e) Using SST, loosen the rack guide spring cap until the
compression spring is not functioning.
SST 09631-10021
(f) Using SST and a torque wrench, tighten the rack guide
spring cap until the preload is within specification.
SST 09616-0001 1, 09631-10021
Preload (turning):
1.2 - 1.5 NVm (12.2 - 15.3 kgfVcm, 10.6 - 13.3 in.Vlbf)
(g) Apply sealant to 2 or 3 threads of the rack guide spring
cap nut.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(h) Temporarily install the rack guide spring cap nut.
(i) Using SST, hold the rack guide spring cap and using
another SST, tighten the rack guide spring cap nut.
SST 09616-0001 1, 09922-10010
Torque: 48 NVm (489 kgfVcm, 35 ftVlbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(j) Precheck the total preload.
Preload (turning):
1.2 - 1.5 NVm (12.2 - 15.3 kgfVcm, 10.6 - 13.3 in.Vlbf)
(k) Remove the RH and LH steering rack ends sub-assy.
Page 757 of 969
F40555
MP Grease
F40538F43004
Vinyl Tape
F41576
SST
SST Fulcrum
Length
C35928
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-35
2610 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(l) Apply MP grease into the control valve, as shown in the
illustration.
(m) Wind vinyl tape around the serration part of the control
valve.
(n) Install the dust cover to the control valve housing.
49. INSTALL STEERING RACK END SUB-ASSY
(a) Install a new 2 claw washers, and temporarily install the
2 steering rack ends sub-assy.
HINT:
Align the claws of the claw washer with the power steering rack
grooves.
(b) Using 2 SSTs, install the 2 steering rack ends sub-assy.
SST 09922-10010
Torque: 58.5 NVm (597 kgfVcm, 43 ftVlbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Using SST, hold the power steering rack and install the
steering rack end sub-assy.
Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).
(c) Using a brass bar and a hammer, stake the claw washer.
NOTICE:
Avoid any impact to the power steering rack.