TOYOTA TERCEL 1996 Service Repair Manual

SR-32
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
12. INSTALL VANE PUMP PULLEY
(a) Install the woodruff key to the vane pump shaft.
(b) Using SST to stop the pulley rotating, torque the pulley set
nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
13. MEASURE PS VANE PUMP ROTATING TORQUE
(See page SR-25)

SR0KQ-03
- STEERINGPOWER STEERING VANE PUMP
SR-33
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Temporarily tighten the 2 bolts (A and B).
2. INSTALL DRIVE BELT
(a) Adjust drive belt tension (See page SR-3).
(b) Torque the A bolt.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(c) Torque the B bolt.
Torque: 39 N´m (400 kgf´cm, 30 ft´lbf)
3. CONNECT PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
Torque: 54 N´m (550 kgf´cm, 40 ft´lbf)
4. CONNECT RETURN HOSE
5. BLEED POWER STEERING SYSTEM
(See page SR-5)

SR0KR-02
R12816
Column Hole Cover
Sliding Yoke
Manual Steering
Gear Assembly
 Cotter Pin Grommet
Bracket
 Non-reusable part Cotter Pin
BracketGrommet SR-34
- STEERINGMANUAL STEERING GEAR
954 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL STEERING GEAR
COMPONENTS

Z19009
 Non-reusable part

Precoated part
Molybdenum disulfide lithium base grease Tie Rod End
Lock Nut
Rack End
 Claw Washer
Steering Rack Rack Housing  Bushing Clip
Clamp Rack Boot
Pinion Bearing Adjusting
Screw Lock Nut

Rack Guide Spring Cap

Rack Guide Spring
Cap Lock Nut
Rack Guide Rack Guide Spring  Oil Seal

Pinion Bearing Adjusting Screw
 Bearing
Steering Pinion
 Bearing
Clamp
Rack Boot
Clip
 Claw Washer
Rack End
Lock Nut
Tie Rod End
- STEERINGMANUAL STEERING GEAR
SR-35
955 Author
: Date
:
1996 TERCEL (RM440U)

SR0KS-01
SR-36
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR-13)
3. REMOVE STEERING WHEEL
(See page SR-13)
4. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA-10)
5. REMOVE COLUMN HOLE COVER
Remove the 4 nuts.
6. DISCONNECT SLIDING YOKE
(See page SR-13)
7. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
8. REMOVE MANUAL STEERING GEAR ASSEMBLY
Remove the gear assembly from the LH side of the vehicle.

SR0KT-01
N00249
SST
N00250
Matchmarks
N00251
R12034
SST
R12035
SST
- STEERINGMANUAL STEERING GEAR
SR-37
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE MANUAL STEERING GEAR IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612-00012
2. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
Place matchmarks on the tie rod end and rack end.
3. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Remove the clamp screw from the boot.
NOTICE:

Be careful not to damage the boot.

Mark the RH and LH boots.
4. REMOVE RH AND LH RACK ENDS AND CLAW
WASHERS
(a) Using a screwdriver and hammer, unstake the washer.
NOTICE:
Avoid any impact on the steering rack.
(b) Using a spanner, hold the steering rack steadily and using
SST, remove the rack end.
SST 09922-10010
NOTICE:

Use SST 09922-10010 in the direction shown in the il-
lustration.

Mark the RH and LH rack ends.
5. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
6. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE
SPRING AND RACK GUIDE
Using a hexagon wrench (19 mm), remove the cap.

R12036
SST
R15598
SSTVinyl Tape
R13864
Cutout Portion SR-38
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
7. REMOVE PINION BEARING ADJUSTING SCREW
LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
8. REMOVE PINION BEARING ADJUSTING SCREW
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the steering pinion.
(b) Using SST, remove the screw.
SST 09612-24014 (09616-10020)
9. REMOVE STEERING PINION WITH BEARING
Fully pull the steering rack from the steering pinion side of the
rack housing and align the rack cutout portion with the pinion.
NOTICE:
Be careful not to damage the serrations.
10. REMOVE STEERING RACK
NOTICE:
To avoid damaging the bushing, remove the rack from the
steering pinion housing side of the rack housing without
revolving it.

SR0KU-02
R13855
Dial Indicator
R14424
SST
F05533
SST
N00343
R15525
SST SST
Bearing
- STEERINGMANUAL STEERING GEAR
SR-39
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout and for
teeth wear and damage.
Maximum runout: 0.30 mm (0.0118 in.)
(b) Check the back surface for wear and damage.
2. IF NECESSARY, REPLACE BEARING
(a) Using SST, remove the bearing.
SST 09950-40010 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04050,
09957-04010, 09958-04010)
NOTICE:
Be careful not to damage the pinion.
(b) Coat a new bearing with molybdenum disulfide lithium
base grease.
(c) Using SST, press in the bearing.
SST 09612-24014 (09612-10061)
NOTICE:
Make sure to install the bearing facing the correct direc-
tion.
3. IF NECESSARY, REPLACE BEARING
(a) Heat the rack housing to above 80°C (176°F).
(b) Using a plastic hammer, tap out the bearing from the rack
housing.
(c) Heat the rack housing to above 80°C (176°F).
(d) Coat a new bearing with molybdenum disulfide lithium
base grease.
(e) Using SST, press in the bearing.
SST 09950-60010 (09951-00340),
09950-70010 (09951-07150)

SR4254
N00345
R14426
SST
Oil Seal
W04041
SST
5 mm
Oil Seal SR-40
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
4. IF NECESSARY, REPLACE BUSHING
(a) Using a screwdriver, depress the projections on the bush-
ing to release the bushing, then remove the bushing from
the rack housing.
(b) Ensure that the hole of the rack housing is not clogged
with grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(c) Coat inside a new bushing with molybdenum disulfide lith-
ium base grease.
(d) Install the bushing into the rack housing, making sure to
align into the 3 holes.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, press out the oil seal from the pinion bearing
adjusting screw.
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
(b) Coat a new oil seal lip with molybdenum disulfide lithium
base grease.
(c) Using SST, press in the oil seal with it is protruding 5 mm
(0.21 in.).
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
NOTICE:
Make sure to install the oil seal facing the correct direction.

SR0KV-01
R13860
Steering
Pinion
Steering
Rack
Cutout Portion
R15598
SSTVinyl Tape
SR4258
SST
- STEERINGMANUAL STEERING GEAR
SR-41
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE
(See page SR-34)
2. INSTALL STEERING RACK
Install the rack into the rack housing.
NOTICE:
To avoid damaging the bushing, install the rack from the
steering pinion side of the rack housing without revolving
it.
3. INSTALL STEERING PINION
(a) Set the steering rack notched side so that the pinion can
be positioned inside.
(b) Line up the cutout portion of the rack with the pinion.
(c) Ensure that the pinion end is securely located in the bear-
ing.
NOTICE:
Do not engage the pinion teeth with the rack teeth.
4. INSTALL PINION BEARING ADJUSTING SCREW
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the steering pinion.
(b) Apply sealant to 2 or 3 threads of the screw.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, temporarily install the screw.
SST 09612-24014 (09616-10020)
5. ADJUST PINION PRELOAD
NOTICE:
Do not engage the pinion teeth with the rack teeth.
(a) Using SST and a torque wrench, tighten the pinion bear-
ing adjusting screw until the preload matches the specifi-
cation.
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
0.4 N´m (3.7 kgf´cm, 3.2 in.´lbf)