TOYOTA AVALON 2001 Service Repair Manual

W03561
Press
SST
Oil Seal SST
SR0RW-03
W02101
SST
Rack Teeth End
R11574
Vinyl TapeBushing
- STEERINGPOWER STEERING GEAR
SR-49
1512 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID OR MOLYBDENUM DISULFIDE
LITHIUM BASE GREASE (See page SR-37)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950- 60010 (09951- 00240, 09951- 00430,
09952-06010), 09950-70010 (09951-07360)
NOTICE:

Make sure that the oil seal is installed facing in the
correct direction.

Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK
(a) Install SST to the steering rack.
SST 09631-33010
HINT:
If necessary, scrape the burrs off the steering rack teeth end
and burnish.
(b) Coat the SST with power steering fluid.
(c) Install the steering rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal lip.
(d) Remove SST.
SST 09631-33010
4. INSTALL BUSHING
(a) Coat a new O-ring with power steering fluid and install it
to the bushing.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the bushing.
NOTICE:

Make sure that the bushing is installed facing in the
correct direction.

Be careful not to damage the oil seal lip.

R11656
Cylinder
End StopperWire SST
R00662
SST
R11657
R11658
R11575
Vinyl Tape SR-50
- STEERINGPOWER STEERING GEAR
1513 Author
: Date
:
2001 AVALON (RM808U)
5. 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 SST, turn the cylinder end stopper clockwise 450
± 50°.
SST 09631-10021
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL RACK HOUSING NO. 2 BRACKET AND
RACK HOSING NO. 2 GROMMET
(a) Install the rack housing No. 2 grommet to the rack housing
No. 2 bracket.
HINT:
Align the projection of the rack housing No. 2 grommet with the
hole of the rack housing No. 2 bracket.
(b) Align the matchmarks on the rack housing No. 2 bracket
and rack housing.
(c) Place the rack housing No. 2 bracket in a vise and install
the vise to fasten the clamp.
8. INSTALL CONTROL VALVE ASSEMBLY
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the control valve shaft.
(b) Coat the teflon rings with power steering fluid.
(c) Install the control valve assembly into the control valve
housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.

W03562
Press
SST
Oil Seal
R11648
SST
R11659
Punch
- STEERINGPOWER STEERING GEAR
SR-51
1514 Author
: Date
:
2001 AVALON (RM808U)
9. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09612-2201 1
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
10. INSTALL CONTROL VALVE HOUSING WITH CON-
TROL VALVE ASSEMBLY
(a) Place a new gasket on the rack housing.
(b) Align the matchmarks on the control valve housing and
rack housing.
(c) Install the 2 bolts.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
11. INSTALL SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and install a new
self-locking nut.
SST 09616-0001 1
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
12. INSTALL DUST SEAL
13. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the rack housing cap.
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(c) Using a punch and hammer, stake the 2 parts of the rack
housing cap.
14. INSTALL RACK GUIDE SUB- ASSEMBLY, RACK
GUIDE SPRING AND RACK GUIDE SPRING CAP
(a) Install the rack guide sub- assembly and rack guide
spring.
(b) 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
(c) Temporarily install the rack guide spring cap.

W03098
SST Rack Guide
Spring Cap
W03099
12°
W03100
SST
W03101
SST
Rack Guide
Spring CapSST SR-52
- STEERINGPOWER STEERING GEAR
1515 Author
: Date
:
2001 AVALON (RM808U)
15. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Using SST, return the rack guide spring cap 12°.
SST 09631-10021
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616-0001 1
(e) Using SST, loosen the rack guide spring cap until the rack
guide 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):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)

W03102
SSTRack Guide
Spring Cap
Lock Nut
SST Fulcrum
Length
R11667
Claw
F03861
Fulcrum
Length
SST
- STEERINGPOWER STEERING GEAR
SR-53
1516 Author
: Date
:
2001 AVALON (RM808U)
16. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the rack guide spring
cap lock nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Temporarily install the rack guide spring cap lock nut.
(c) Using SST, hold the rack guide spring cap and using
another SST torque the rack guide spring cap lock nut.
SST 09631-10021, 09922-10010
Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
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.).
(d) Recheck the total preload.
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
(e) Remove the RH and LH rack ends.
17. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new claw washer, and temporarily install the rack
ends.
HINT:
Align the claws of the claw washers with the steering rack
grooves.
(b) Using a spanner (24 mm), hold the steering rack steadily
and using SST, torque the rack end.
SST 09922-10010
Torque: 60 N´m (610 kgf´cm, 44 ft´lbf)
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.).

R11668
Brass Bar
R11669
W04223
2 mm
(0.79 in.)
or less
SST
R00429
Matchmarks SR-54
- STEERINGPOWER STEERING GEAR
1517 Author
: Date
:
2001 AVALON (RM808U)
(c) Using a brass bar and hammer, stake the claw washer.
NOTICE:
Avoid any impact on the steering rack.
(d) Employ the same manner described above to the other
side.
18. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Ensure that the steering rack hole is not clogged with
grease.
HINT:
If the hole is clogged, the pressure inside the rack boot will
change after it is assembled and the steering wheel is turned.
(b) Install the rack boot, clip and a new clamp.
NOTICE:
Be careful not to damage or twist the rack boot.
(c) Using SST, tighten the clamp as shown in the illustration.
SST 09521-24010
(d) Employ the same manner described above to the other
side.
19. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the lock nut (See page
SA-4).
Torque: 74 N´m (750 kgf´cm, 54 ft´lbf)
(c) Employ the same manner described above to the other
side.

F13588SST
Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-55
1518 Author
: Date
:
2001 AVALON (RM808U)
20. INSTALL 2 TURN PRESSURE TUBES
(a) Coat 4 new O-rings with power steering fluid and install
them to the 2 turn pressure tubes.
(b) Using SST, install the 2 turn pressure tubes.
SST 09023-38200
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.

SR0EU-05
F13586
SST
SR-40
- STEERINGPOWER STEERING GEAR
1503 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
NOTICE:
Remove the steering wheel assembly before the steering
gear removal, because there is possibility of breaking of
the spiral cable.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD (See page SR-12)
3. REMOVE STEERING WHEEL (See page SR-12)
4. DISCONNECT RH AND LH TIE ROD ENDS (See page
SA-9)
5. DISCONNECT INTERMEDIATE SHAFT SUB- AS-
SEMBLY (See page SR-12)
6. DISCONNECT CLAMP PLATE
Remove the nut and clamp plate.
7. DISCONNECT PRESSURE FEED AND RETURN
TUBES
(a) Using SST, disconnect the pressure feed and return
tubes.
SST 09023-38400
(b) Remove the 2 O-rings from the pressure feed and return
tubes.
8. DISCONNECT STABILIZER BAR
Remove the 4 bolts and disconnect the stabilizer bar.
HINT:
Do not remove the stabilizer bar.
9. REMOVE NO. 1 FUEL TUBE PROTECTOR
Remove the 2 bolts, nut and No. 1 fuel tube protector.
10. REMOVE PS GEAR ASSEMBLY
(a) Remove the 2 PS gear assembly set bolts and nuts.
HINT:
Lift up the stabilizer bar and remove the bolts.
(b) Remove the PS gear assembly from the LH of the vehicle.
NOTICE:
Do not damage the turn pressure tubes.

SR0RX-02
F01792
Press
SST
Oil Seal
Bearing
W03560
Press
SST
Oil SealSST
F03877
PressSST
SST Bearing
F01794
Brass Bar
Bearing
F01795
Press
SST
Bearing
SR-46
- STEERINGPOWER STEERING GEAR
1509 Author
: Date
:
2001 AVALON (RM808U)
REPLACEMENT
NOTICE:
When using a vise, do not over tighten it.
1. IF NECESSARY, REPLACE OIL SEAL AND BEARING
(a) Using SST, press out the oil seal and bearing from the
control valve housing.
SST 09950-60010 (09951-00250),
09950-70010 (09951-07200)
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00320,
09952-06010), 09950-70010 (09951-07200)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
(d) Coat a new bearing with molybdenum disulfide lithium
base grease.
(e) Using SST, press in the bearing.
SST 09950-60010 (09951-00180, 09951-00340,
09952-06010), 09950-70010 (09951-07200)
2. IF NECESSARY, REPLACE 2 BEARINGS
(a) Using a brass bar and hammer, tap out the bearing from
the rack housing.
(b) Using SST, press out the bearing from the rack housing.
SST 09950-60010 (09951-00260),
09950-70010 (09951-07200)

F03878
PressSST
SST
Bearing
F01797
Press
SST
Bearing
F01798SST
BushingOil
Seal
SST
F03863
Press
Oil Seal
SST
SST
R10955
- STEERINGPOWER STEERING GEAR
SR-47
1510 Author
: Date
:
2001 AVALON (RM808U)
(c) Coat a new bearing with molybdenum disulfide lithium
base grease.
(d) Using SST, press in the bearing.
SST 09950-60010 (09951-00250, 09951-00310,
09952-06010), 09950-70010 (09951-07200)
(e) Coat a new bearing with molybdenum disulfide lithium
base grease.
(f) Using SST, press in the bearing.
SST 09950-60010 (09951-00320),
09950-70010 (09951-07200)
3. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, remove the oil seal from the bushing.
SST 09527-2001 1, 09612-24014 (09613-22011)
NOTICE:
Be careful not to damage the bushing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST, press in the oil seal.
SST 09950-60010 (09951-00240, 09951-00400,
09952-06010)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
4. IF NECESSARY, REPLACE TEFLON RING AND O-
RING
(a) Using a screwdriver, remove the teflon ring and O-ring
from the steering rack.
NOTICE:
Be careful not to damage the groove for the teflon ring.
(b) Coat a new O-ring with power steering fluid and install it.