Replacement Of Gear Housing

IF NECESSARY, REPLACE FOLLOWING PARTS:

1. OIL SEAL FOR RACK HOUSING

(a) Remove the oil seal with a screwdriver.

(b) Using SST, install the new oil seal.

SST 09620 30010 (09631 00020) SST 09630-24013 (09631-24070)

2. OIL SEAL FOR CYLINDER HOUSING

(a) Using SST, drive out the oil seal.

(b) Using SST and a hammer, install a new oil seal. SST 09620-30010 (09625 30010. 09631-00020)

• Place the spacer on the oil seal.

• Drive in the oil seal over the spacer until the round surface of SST is flush with housing surface.

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OIL SEAL AND BEARING FOR CONTROL VALVE HOUSING

(a) Remove the snap ring.

(b) Remove the bearing and oil seal with brass bar.

How Fit Toyota Hilux Diff Bearing

ZS649

(c) Install the new bearing and oil seal.

(d) Install the snap ring.

PINION LOWER BEARING

(a) Remove the bearing with brass bar.

(b) Install a new bearing.

TEFLON RING AND O-RING

(a) Remove the teflon ring and O-ring.

(c) Install a new teflon ring to SST and install it to the steering rack.

SST 09630-24013 (09631-24020)

(d) Coat the teflon ring with power steering fluid and snug it down with your fingers.

(e) Carefully slide the tapered end of SST over the teflon ring to seat the ring.

SST 09630 24013 (09631-24030)

NOTE: Make sure the seal is uniformly spaced around the perimeter of the piston.

ZS649

Teflon Rings

6. TEFLON RING FOR CONTROL VALVE

(a) Remove the teflon rings.

CAUTION: Be careful not to damage the control valve.

Engine Cam Bearings And Journal

(b) Install a new teflon ring to SST and install it to the control valve.

SST 09630 24013 (09631-24020)

(c) Coat the teflon ring with power steering fluid and snug it down with your fingers.

(d) Carefully slide the tapered end of the SST over the teflon ring to seat the ring.

SST 09630-24013 (09631-24030)

7. OIL SEAL AND BEARING FOR VALVE CAP

(a) Using SST, press out the oil seal and bearing from the valve cap.

SST 09620-30010 (09631-00020) 09630-24013 (09620-24010)

(b) Using SST, press the oil seal into the valve cap.

SST 09620-30010 (09631-00020) 09630-24013 (09620-24020)

(c) Using SST, press the bearing into the valve cap.

SST 09620-30010 (09631 00020) 09630-24013 (09620-24030)

8. OIL SEAL FOR CYLINDER END STOPPER

(a) Tap out the oil seal from the cylinder end stopper.

CAUTION: When tapping out the oil seal, be careful not to damage the inside of cylinder end stopper.

(b) Using SST, press the oil seal into the cylinder end stopper.

SST 09631-20040

Cremailler Jaguar Type

: Molybdenum Disulphide Lithium 8ase Grease <$=>: Power Steering Fluid

ASSEMBLY OF GEAR HOUSING

1. COAT POWER STEERING FLUID ON FOLLOWING PARTS:

: Molybdenum Disulphide Lithium 8ase Grease <$=>: Power Steering Fluid

2. INSTALL SEAT AND SPACER

3. INSTALL STEERING RACK ASSEMBLY

(a) Insert SST into a new teflon ring of the piston.

SST 09630 24013 (09631-24030)

NOTE: Protect the teflon ring from damage.

(b) Insert SST into a new oil seal of the cylinder housing.

• Install one SST into the other.

• Insert two SST into the oil seal.

• Remove one SST from the other.

SST 09630-24013 (09631-24041,09631-24050) NOTE: Protect the oil seal lip from damage.

Cylinder Housing

(c) Install the steering rack to the cylinder housing.

SST 09630-24013 (09631-24030. 09631-24041)

4. INSTALL RACK END GUIDE AND WAVE WASHER

Install the rack end guide with oil groove facing toward the staked groove.

5. INSTALL CYLINDER END STOPPER WITH ORING

(a) Insert SST to the oil seal of the cylinder end stopper.

• Install one SST into the other.

• Install two SST into the oil seal.

• Remove one SST from the other.

(b) Install the cylinder end stopper to the cylinder housing.

SST 09630-24013 (09631-24041,09631-24050)

6. INSTALL RACK HOUSING TO CYLINDER HOUSING

NOTE: Make sure that the O ring, spacer and seal are installed between the rack housing and the cylinder hout-ing.

(a) Install the rack housing.

(b) Install the four bolts and torque them. Torque: 185 kg-cm (13 ft-lb, 18 Nm)

7. INSTALL CYLINDER END STOPPER NUT

(a) Coat liquid sealer onto the screw surface of the new nut.

(b) Install the cylinder end stopper nut with SST and torque the nut.

SST 09630-24013 (09631-24060)

(c) Stake the end stopper nut to the cylinder housing flange.

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8. INSTALL CLAW WASHER AND RACK ENDS

(a) Install the claw washer.

NOTE: Align the claw of the claw washer with the rack groove.

(b) Tighten the rack end and torque it with SST. SST 09612-24012 (09617-22030, 09617-24010) Torque: 1,050 kg-cm (76 ft-lb, 103 Nm)

(c) Stake the claw washer.

9. INSTALL CONTROL VALVE ASSEMBLY INTO CONTROL VALVE HOUSING

10. INSTALL CONTROL VALVE SPRING SEAT

11. INSTALL COMPRESSION SPRING

12. INSTALL O-RING AND CONTROL VALVE HOUSING TO RACK HOUSING

(a) Align the marks on the control housing and rack housing.

(b) Coat liquid sealer onto the screw surface of the bolt.

(c) Install the three bolts and torque them. Torque: 185 kg-cm (13 ft-lb, 18 N m)

13. ADJUST CONTROL VALVE SHAFT PRELOAD

(a) Coat liquid sealer onto the screw surface of the bolt.

(b) Tighten the pinion adjusting screw and torque with SST.

SST 09612-24012 (09612-10021) Torque: 150 kg-cm (11 ft-lb, 15 N m)

(c) Return the pinion adjusting screw 10°.

(d) Using SST, measure the preload. SST 09616-00010

(3.9 - 5.6 in.-lb, 0.4 - 0.6 N m) If incorrect, readjust.

14. INSTALL PINION ADJUSTING SCREW LOCK NUT

(a) Coat liquid sealer onto the lock nut and gear housing contact surfaces.

(b) Install the pinion adjusting screw lock nut and torque it with SST.

SST 09612-24012 (09612-10021,09617-24020) Torque: 700 kg-cm (51 ft-lb, 69 N m)

(c) Recheck the control valve shaft preload.

15. INSTALL SEAT AND RACK GUIDE

16. INSTALL RACK GUIDE SPRING AND CAP

(a) Install the rack guide spring.

(b) Coat liquid sealer onto the screw surface of the cap.

(c) Using SSTf install the rack guide spring cap. SST 09612-24012(09612-10021)

17. ADJUST TOTAL PRELOAD

(a) Tighten the rack guide spring cap with SST and torque it.

(b) Using SST, return the rack guide spring cap 90°.

(c) Using SST, measure the preload.

SST 09616 00010

Preload (turning): 9-12 kg-cm

If incorrect, readjust.

18. INSTALL RACK GUIDE SPRING CAP LOCK NUT

(a) Coat liquid sealer onto the lock nut and gear hogsinj contact surfaces.

(b) Tighten the rack guide spring cap lock nut and torque it with SST.

SST 09612-24012 (09612-10021, 09617-24020) Torque: 700 kg-cm (51 ft-lb, 69 N m)

(c) Recheck the total preload.

If incorrect, readjust.

Preload (turning): 9-12 kg-cm

19. INSTALL DUST COVER

20. INSTALL RACK BOOTS, CLAMPS AND CLIPS

(a) Insure that the tube hole is not clogged with grease.

NOTE: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the handle turned.

(b) Install boots.

NOTE: As the left and right boots are different, be careful not to interchange them.

Straight Line

Tube Side

Pinion Side

8-9 mm

5-6 mm

<0.31 - 0.35 in.)

<0.20 - 0.24 in.)

ZS900

(c) Install the rack boot clamps as shown in the figure.

(d) Install rack boot clips.

NOTE: Face the open ends outward, as shown, to avoid damage to the boots.

21. INSTALL TIE ROD

(a) Align the marks on the tie rod and rack end.

(b) Tighten the nuts and torque them. Torque: 175 kg-cm (13 ft-lb, 17 N-m)

22. INSTALL RIGHT AND LEFT TURN PRESSURE TUBES

(a) Install the union seats.

(b) Using SST. tighten the tubes and torque them. SST 09631-22020

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