TOYOTA TERCEL 1996 Service Repair Manual

SR4282
SST
SR-52
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
15. REMOVE STEERING RACK WITH OIL SEAL
(a) Using SST, press out the rack with the oil seal.
SST 09612-24014 (09612-10061)
NOTICE:
Take care not to drop the rack.
(b) Remove the oil seal from the rack.
16. REMOVE SPACER AND OIL SEAL
Using SST and a hammer, drive out the spacer and oil seal.
SST 09950-60010 (09951-00220),
09950-70010 (09951-07360)
NOTICE:
Do not damage the rack housing.

SR0L0-02
R10072
Dial Indicator
R11358
Cylinder Gauge
Micrometer
Bushing
R11357
BushingSST Steel
Plate
R11359
Brass Bar
Oil Seal
- STEERINGPOWER STEERING GEAR
SR-53
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
Using a dial indicator, check the rack for runout and teeth wear
and damage.
Maximum runout: 0.30 mm (0.0118 in.)
2. MEASURE OIL CLEARANCE BETWEEN CONTROL
VALVE ASSEMBLY AND BUSHING
Using a micrometer and a cylinder gauge, measure the oil clear-
ance.
Standard clearance:
0.050 - 0.083 mm (0.00197 - 0.00327 in.)
Maximum clearance: 0.125 mm (0.00492 in.)
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL
(a) Using SST and 2 steel plates, remove the bushing from
the rack housing.
SST 09612-65014 (09612-01030)
NOTICE:

As shown, from the opposite side of SST confirm that
its claw is firmly caught on the bushing.

Be careful not to damage the rack housing.
(b) Using a brass bar and a hammer, remove the oil seal from
the rack housing.
NOTICE:
Be careful not to damage the rack housing.
(c) Coat a new oil seal lip with power steering fluid.
(d) Using a socket wrench (24 mm), extension bar and ham-
mer, press in the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.

R10955
R06172
Z06082
Z01716
SR-54
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
(e) Using a socket wrench (24 mm) and a extension bar, care-
fully press in a new bushing to a depth of 73 mm (2.87 in.).
NOTICE:
If the bushing is pushed in too far, it will cause deformation
of the rack housing. If it is not pushed in far enough, it will
interfere with the control valve assembly. Therefore, al-
ways use a press and install the bushing to the proper
depth. Then, install the control valve assembly and ensure
that it rotates smoothly.
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.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the ring.
(d) Coat the ring with power steering fluid.
(e) Install the ring to the steering rack and settle it down with
your fingers.
5. IF NECESSARY, REPLACE TEFLON RINGS
(a) Using a screwdriver, remove the 4 rings from the control
valve assembly.
NOTICE:
Be careful not to damage the grooves for the ring.
(b) Expand 4 new teflon rings with your fingers.
NOTICE:
Be careful not to overexpand the ring.

F05317
SST
- STEERINGPOWER STEERING GEAR
SR-55
1996 TERCEL (RM440U)
(c) Coat the rings with power steering fluid and install them
to the control valve, and settle them down with your fin-
gers.
(d) Carefully slide the tapered end of SST over the rings until
the rings fit to the control valve assembly.
SST 09631-20081
NOTICE:
Be careful not to damage the rings.

SR1F1-01
R14429
W02101
SST
Rack Teeth End SR-56
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR
MOLYBDENUM DISULFIDE LITHIUM BASE GREASE
(See page SR-46)
2. INSTALL OIL SEAL AND SPACER
(a) Coat a new oil seal lip with power steering fluid.
(b) Install the oil seal and spacer to SST, and drive in them
with a plastic hammer.
SST 09950-60010 (09951-00220, 09951-00380,
09952-06010), 09951-70010 (09951-07360)
NOTICE:

Make sure to install the oil seal facing 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 rack.
SST 09631-10041
HINT:
If necessary, scrape the burrs off the rack teeth end and bur-
nish.
(b) Coat SST with power steering fluid.
(c) Insert the rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal.
(d) Remove the SST.

Z03128
Vinyl Tape
R11057
SST
SR4264
SST
- STEERINGPOWER STEERING GEAR
SR-57
1996 TERCEL (RM440U)
4. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the oil seal by pushing it into the rack housing, with-
out tilting.
NOTICE:
Make sure to install the oil seal facing the correct direction.
5. INSTALL BUSHING AND CYLINDER END STOPPER
(a) Install a new bushing to the stopper.
(b) Using SST, torque the stopper.
SST 09631-20090
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(c) Using a punch and a hammer, stake the stopper and rack
housing.
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071
NOTICE:
Do not install union seats.
(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 CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) Push the valve assembly into the rack housing.

Z13779
SST
Bearing
W04072
SST
Bearing Press
Oil Seal
SR4281
SST
Z13781
Punch SR-58
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
8. INSTALL BEARING
Using SST, press in a new bearing.
SST 09612-2201 1
9. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal until it contacts the bear-
ing.
SST 09612-2201 1
NOTICE:
Make sure to install the oil seal facing the correct direction.
(c) Using snap ring pliers, install a new snap ring to the rack
housing.
10. INSTALL SELF-LOCKING NUT
(a) Coat a new bearing with molybdenum disulfide lithium
base grease and install it to the control valve shaft.
(b) Using SST, stop the control valve shaft rotating and
torque a new nut.
SST 09616-00010
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
11. 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 or equivalent
(b) Torque the cap.
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(c) Using a punch and a hammer, stake the cap at 2 places.
12. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK
GUIDE SPRING, AND RACK GUIDE SPRING CAP
(a) Install the seat to the guide.
(b) Install the guide to the rack housing.
(c) Apply sealant to 2 or 3 threads of the spring cap.
Sealant: Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(d) Temporarily install the cap.

W04432
Hexagon
Wrench
12°
W00840
SST
W00841
SST
Hexagon
Wrench
W01203SSTHexagon
Wrench Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-59
1996 TERCEL (RM440U)
13. 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 a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Using a hexagon wrench (21 mm), return the cap 12°.
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616-00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (21
mm), tighten the cap until the preload is within the specifi-
cation.
SST 09616-00010
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
14. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (21 mm), hold the rack guide
spring cap and using SST, torque the nut.
SST 09922-10010
Torque: 36 N´m (366 kgf´cm, 26 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 300 mm (11.81
in.).
(c) Recheck the total preload.
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
(d) Remove the RH and LH rack end.

R07337
Rack Groove
R11031
SST
Fulcrum
Length
R10934
Brass
Bar
F05319
SR4273
0 - 3 mm
(0 - 0.12 in.) SR-60
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
15. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922-10010
Torque: 51 N´m (520 kgf´cm, 18 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.).
(c) Using a brass bar and a hammer, stake the washer.
NOTICE:
Avoid any impact on the rack.
16. 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 boot will change
after it is assembled and the steering wheel is turned.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boots.
(c) Tighten a new clamp, as shown in the illustration.

R13123
R11032
SST
Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-61
1996 TERCEL (RM440U)
(d) Install the clip.
HINT:
Face the open ends of the clip outward/upward, as shown.
17. 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 nut
(See page SA-4).
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
18. INSTALL AIR CONTROL VALVE
Torque the valve.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
19. INSTALL 2 TURN PRESSURE TUBES
(a) Install 2 new union seats.
(b) Using SST, install the tube.
SST 09633-00020
Torque: 20 N´m (203 kgf´cm, 15 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

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