LEXUS SC400 1991 Service Repair Manual

10. REMOVE SELF±LOCKING NUTUsing SST to hold the control valve shaft, remove the self±
locking nut.
SST 09616±00010
11. REMOVE DUST COVER
12. REMOVE CONTROL VALVE HOUSING
(a) Using a hexagon wrench, remove the 2 bolts.
(b) Pull out the valve with the valve housing.
(c) Remove the O±ring from the valve housing.
13. REMOVE CONTROL VALVE Using a plastic hammer, tap out the control valve.
14. REMOVE LOWER BEARING AND SPACER
15. REMOVE CYLINDER END STO PPER, SPACERS, OIL
SEAL AND RACK
(a) Using snap ring pliers, remove the snap ring.
SR±152
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STEERING POWER STEERING
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(b) Using SST, press the rack until the end stopper slightlytouches the press block.
SST 09612±24014 (09612±10061)
(c) Slightly tap the rack end with a brass bar and hammer.
(d) Pull out the rack with cylinder end stopper, 2 spacers and oil seal.
16. REMOVE RACK HOUSING OIL SEAL AND SPACER Using SST, tap out the oil seal and spacer.
SST 09631±12020, 09631±20031
GEAR HOUSING COMPONENTS
INSPECTION AND REPAIR
SR0NZ±01
1. INSPECT RACK
(a) Using a dial indicator, check the rack for runout and for teethwear or damage.
Maximum runout:
0.3 mm (0.012 in.)
(b) Check the back surface for wear or damage.If faulty, replace it.
2. IF NECESSARY, REPLACE RACK HOUSING BEARING AND OIL SEAL
(a) Using SST, remove the bearing. SST 09612±30012
NOTICE: Be careful not to damage the rack housing.
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STEERING POWER STEERINGSR±153
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(b) Using SST, remove the oil seal.SST 09612±30012
NOTICE: Be careful not to damage the rack housing.
HINT: When using the SST, apply the tips of the SST to the
cutouts in the housing.
(c) Coat a new oil seal lip with power steering fluid.
(d) Using SST, install the new oil seal. SST 09620±30010 (09624±30010, 09631±00020)
NOTICE: Ensuse that the oil seal facing the correct direction.
(e) Using SST, press in a new bearing.
SST 09620±30010 (09626±30010, 09631±00020)
3. IF NECESSARY, REPLACE CONTROL VALVE HOUSING OIL SEAL AND BEARING
(a) Using SST, press out the oil seal with the bearing.
SST 09630±24013 (09620±24010), 09631±12020
(b) Coat the lip of a new oil seal with power steering fluid.
(c) Using SST, press in the new oil seal. SST 09630±24013 (09620±24020),
09631±12020
NOTICE: Ensure that the oil seal facing the correct direction.
SR±154±
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(d) Using SST, press in a new bearing.SST 09630±24013 (09620±24030), 09631±12020
4. IF NECESSARY, REPLACE STEERING RACK TEFLON RING AND O±RING
(a) Using a screwdriver, remove the teflon ring and O±ring.
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.
(c) Expand a new teflon ring with your fingers.
NOTICE: Be careful not to over±expand the teflon ring.
(d) Install the teflon ring to the rack.
(e) Coat the teflon ring with power steering fluid and snug it down
with your fingers.
5. IF NECESSARY, REPLACE CONTROL VALVE TEFLON RINGS
(a) Using a screwdriver, remove the 4 teflon rings.
NOTICE: Be careful not to damage the grooves for the teflon
ring.
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STEERING POWER STEERINGSR±155
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(b) Expand 4 new teflon rings with your fingers.
NOTICE: Be careful not to over±expand the teflon ring.
(c) Install the 4 teflon rings to the control valve.
(d) Coat the 4 teflon rings with power steering fluid and snugthem down with your fingers.
(e) Carefully slide the tapered end of the SST over the teflon rings to seat the rings.
SST 09631±20081
NOTICE: Be careful not to damage the teflon rings.
6. IF NECESSARY, REPLACE HY DRAULIC REACTION
CHAMBER TEFLON RINGS AND O±RINGS
(a) Using a screwdriver, remove the 2 teflon rings and 2 O ±rings.
NOTICE: Be careful not to damage the grooves for the teflon
ring.
(b) Coat 2 new O±rings with power steering fluid, and install
them.
(c) Expand 2 new teflon rings with your fingers.
NOTICE: Be careful not to over±expand the teflon rings.
(d) Install the 2 teflon rings to the control valve.
(e) Coat the teflon rings with power steering fluid, and snug them
down with your fingers.
(f) Carefully slide the tapered end of the SST over the teflon rings to seat the rings.
SST 09631±32020
NOTICE: Be careful not to damage the teflon rings.
SR±156±
STEERING POWER STEERING
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7. IF NECESSARY, REPLACE PRESSURE CONTROLVA LV E
(a) Using a hexagon wrench, remove the 3 bolts.
(b) Remove the 3 O±rings from the housing.
(c) Coat 3 new O±rings with power steering fluid, and install them on the control valve housing.
(d) Using a hexagon wrench, install a new pressure control valve
with the 3 bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
STEERING GEAR HOUSING ASSEMBLY
SR0P0±01
1. COAT WITH POWER STEERING FLUID OR
MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE
(See page SR±148)
2. INSTALL RACK HOUSING OIL SEAL AND SPACER
(a) Coat a new oil seal lip with power steering fluid.
(b) Insert SST into the oil seal and spacer. SST 09631±12020, 09631±32010
NOTICE:
w Make sure you install the oil seal facing the correct
direction.
w Take care that the oil seal does not get reversed as you
install it.
(c) Softly tap in the spacer and oil seal.
±
STEERING POWER STEERINGSR±157
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3. INSTALL STEERING RACK
(a) Install SST to the steering rack.HINT: If necessary, scrape the burrs off the steering rack
teeth end and burnish.
SST 09631±20102
(b) Coat SST with power steering fluid.
(c) Insert the rack into the cylinder.
(d) Remove SST.
4. INSTALL CYLINDER END STOPPER, OIL SEAL AND SPACERS
(a) To prevent oil seal lip damage, wind vinyl tape on the steering
rack end, and apply power steering fluid.
(b) Install the oil seal by pushing it into the cylinder, wit hout tilting.
NOTICE:
wMake sure you install the oil seal facing the correct
direction.
w Take care that the oil seal does not get reversed as you
install it.
(c) Install the 2 spacers.
(d) Using SST, drive in the cylinder end stopper.
SST 09620±30010 (09627±30010, 09631±00020)
SR±158
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(e) Using snap ring pliers, install a new snap ring.
5. AIR TIGHTNESS TEST
(a) Install SST to the unions of the rack housing.SST 09631±12071
(b) Apply 53.3 kPa (400 mmHg, 15.75 inVHg) 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
rack housing oil seals.
6. INSTALL CONTROL VALVE
(a) Coat the teflon rings with power steering fluid.
(b) Push the control valve into the rack housing.
7. INSTALL CONTROL VALVE HOUSING
(a) Coat a new O±ring with power steering fluid, and install it to the valve housing.
(b) Using a hexagon wrench, tighten the 2 bolts.
Torque: 18 N Vm (185 kgf Vcm, 13 ft Vlbf)
NOTICE: To prevent oil seal lip damage, wind vinyl tape on the
serration part of the control valve shaft.
8. INSTALL LOWER BEARING AND SPACER
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STEERING POWER STEERINGSR±159
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9. INSTALL SELF±LOCKING NUTUsing SST to hold the control valve shaft, install a new self±
locking nut.
SST 09616±00010
Torque: 39 N Vm (400 kgf Vcm, 29 ft Vlbf)
10. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 for equivalent
(b) Install the cap.
Torque: 69 N Vm (700 kgf Vcm, 51 ft Vlbf)
11. INSTALL RACK GUIDE SEAT, RACK GUIDE AND RACK
GUIDE SPRING
12. ADJUST TOTAL PRELOAD
(a) Apply sealant to 2 or 3 threads of the spring cap.
Sealant: Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using SST, install and torque the spring cap.SST 09612±24014 (09612±10022)
Torque: 25 N Vm (250 kgf Vcm, 18 ft Vlbf)
(c) Using SST, return the rack guide spring cap 125
SST 09612±24014 (09612±10022)
(d) Using SST, turn the control valve shaft right and left 1 or 2
times.
SST 09616±00010
(e) Loosen the spring cap until the rack guide compression spring is not functioning.
SR±160
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STEERING POWER STEERING
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(f) Using SST and a torque meter, tighten the rack guide springcap until the preload is within specification.
SST 09612±24014 (09612±10022)
09616±00010
Preload (turning):
0.9±1.9 N Vm (9±20 kgf Vcm 7.9±17.3 in. Vlbf)
13. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the lock nut.
Sealant:
Part No. 08833±00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using SST, install and torque the lock nut.SST 09612±24014 (09612±10022, 09617±24020)
Torque: 56 N Vm (570 kgf Vcm, 41 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 340 mm
(13.39 in.).
(c) Recheck the total preload.
Preload (turning):
0.9±1.9 N Vm (9±20 kgf Vcm 7.9±17.3 in. Vlbf)
14. INSTALL DUST COVER
15. INSTALL CLAW WASHERS AND RACK ENDS
(a) Install new claw washer.
HINT: Align the claws of the claw washer with the rack
grooves.
(b) Using SST, install and torque the rack end. SST 09612±24014 (09617±24011)
09617±14010
Torque: 92 N Vm (940 kgf Vcm, 68 ft Vlbf)
HINT: Use a torque wrench with a fulcrum length of 340 mm
(13.39 in.).
(c) Using a brass bar and hammer, stake the claw washer.
±
STEERING POWER STEERINGSR±161
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