Gear Housing

REMOVAL

Remove the parts in the numerical order shown in the figure.

Toyota Tercel Pitman

1. Dust Cover or Heat Insulator

2. Dust Cover

3. Fluid Return Hose & Fluid Pressure Hose

4. Intermediate Shaft Yoke or Main Shaft Coupling

5. Pitman Arm

6. Gear Housing

Fig. 8-356

Fig. 8-356

Disconnect the return hose with SST. SST [09631-22020]

0 Disconnect the pressure hose with SST. SST [09631-22020]

Fig. 8-358

Fig. 8-358

Remove the coupling set bolt.

Fig. 8-359

Remove the coupling set bolt.

r I | l Remove the steering column tube set bolts. Loosen the upper bracket set bolts.

Disconnect the relay rod with SST. SST [09611-20014]

Fig. 8-361

Fig. 8-361

0 Remove the pitman arm with SST. SST [09610-55012]

Fig. 8-362

Fig. 8-362

Remove the pitman arm with SST. SST [09610-55012]

Remove the coupling from the steering gear housing.

Remove the coupling from the steering gear housing.

Remove the pitman arm with SST. SST [09610-55012]

DISASSEMBLY

Disassemble the parts in the numerical order shown in the figure.

Fig. 8-364

4 Fig. 8-368 8-369

1. Lock Nut

3. Cross Shaft

4. Power Piston & Valve Body

5. 0 Ring 6 Housing

Fig. 8-365

Fig. 8-365

Fig. 8-366

Clamp the gear housing in a vice.

Fig. 8-366

0 Tighten the adjusting screw until the end cover and 0 ring are removed from the housing.

Fig. 8-367

Fig. 8-367

0 Remove the cross shaft by tapping the bottom end with a hammer.

Fig. 8-368

0Hold the power piston with your finger and turn the worm shaft clockwise. Then pull out the valve body and power piston.

Fig. 8-369

Do not disassemble the valve body. Do not remove the power piston nut from the worm shaft.

Fig. 8-371

INSPECTION & REPAIR End Cover

Inspect the following for wear or damage.

1. Needle roller bearing

2. 0 ring groove

Cross Shaft

Inspect the following for wear or damage.

1. Needle roller bearing running surface

2. Teflon ring contact surface

3. Dust seal contact surface

4. Power piston nut gear tooth contact surface

Fig. 8-372

Fig. 8-372

2. Unstake the lock nut.

3. Loosen the lock nut with SST.

SST (09632-00030) of set [09630-00010]

Adjust The Cross Shaft Adjusting Screw

1. Measure the thrust clearance of the adjusting screw. Clearance: 0.03-0.05 mm

2. Unstake the lock nut.

3. Loosen the lock nut with SST.

SST (09632-00030) of set [09630-00010]

Fig. 8-374

Fig. 8-374

Fig. 8-375

Fig. 8-375

4. Adjust the clearance of the adjusting screw by turning the lock nut.

5. Stake the lock nut.

Power Piston Nut

1. Inspect the following for wear or damage.

(1) Cross shaft gear tooth contact surface

(2) Teflon ring

(3) 0 ring groove

Fig. 8-376

Fig. 8-376

Fig. 8-377

Measure the ball clearance. Clearance:

0 Adjusting Plug & Worm Bearing

1. Support the valve body by installing it to the gear housing.

Fig. 8-378

Fig. 8-378

Fig. 8-381

2. Remove the lock nut with SST.

SST (09631-00040) of set [09630-00010]

3. Remove the adjusting plug with SST. SST (09631-00050) of set [09630-00010]

4. Inspect the following for wear or damage.

(2) O ring contact surface

(3) Bearing

5. Install the adjusting plug provisionally.

(2) Install the bearing.

(3) Install the adjusting plug provisionally with SST.

SST (09631-00050) of set [09630-00010]

(4) Remove the valve body and the power piston nut from the gear housing.

Fig. 8-382

Fig. 8-382

Fig. 8-383

Gear Housing

Inspect the following for wear or damage.

1. Needle roller bearing

2. Teflon ring

3. Dust seal

Fig. 8-383

Fig. 8-384

0 Replace The Needle Roller Bearing

1 Remove the dust seal with a screwdriver.

2. Remove the snap ring.

3. Remove the teflon ring.

Fig. 8-384

-SST

-SST

4. Remove tne needle roller bearing with SST.

SST (09631-00080) of set [09630-00010]

Fig. 8-385

Longer edge of outer race is facing outwards m

Longer edge of the outer race is facing outwards.

Longer edge of the outer race is facing outwards.

5. Install the needle roller bearing with the longer edge of the outer race facing outwards.

Fig. 8-386

Install the needle roller bearing with SST. SST (09631-00090) of set [09630-00010] [09631-60010] FJ. HJ6 _ series FJ, HJ4 _ series Installed position: FJ, HJ6 _ Series

23.1 mm (0.909 in.) FJ, HJ4 _ Series 23.6 mm (0.929 in.)

Fig. 8-387

Fig. 8-387

The bearing top end should be installed so that is aligns with the housing end surface.

SST (09631-00090) of set [09630-00010]

Fig. 8-388

Fig. 8-388

The bearing top end should be installed so that is aligns with the housing end surface.

SST (09631-00090) of set [09630-00010]

Install the teflon ring and O ring. FJ, HJ6 _ series

(1) Install the O ring, spacer and snap ring.

(2) Form the teflon ring into a heart shape and install with your finger.

Fig. 8-389

Fig. 8-389

'SST

(1) Install the teflon ring together the O ring to SST.

SST [09631-60010]

(2) Install SST together with the rings to the gear housing.

SST [09631-60010]

Fig. 8-390

Fig. 8-390

(3) Install the steel ring and the snap K+l ring.

Comfirm that the steel ring can be turned by hand.

Fig. 8-391

Fig. 8-391

9. Rub SST along the inside of the teflon ring so that it will fit smoothly over the cross shaft.

SST (09631-00060) of set [09630-00010]

Fig. 8-392

Fig. 8-392

010. Install the dust seal with SST.

SST (09631-00010) of set [09630-00010]

ASSEMBLY

Assemble the parts in the numerical order shown in the figure.

Fig. 8-393

1. Housing

3. Power Piston & Valve Body

4. End Cover, 0 Ring & Cross Shaft

5. Lock Nut & Seal Washer

Fig. 8-394

Fig. 8-394

Fit the 0 ring accurately.

Fig. 8-395

Fig. 8-395

Tighte n the bolts diagonally and evenly in two " * or three rotations.

Fig. 8-396

Fig. 8-396

Tighten the valve body. Tightening torque:

Fig. 8-397

Fig. 8-397

0 Adjust the preload of the worm shaft.

1. Tighten the adjusting plug with SST. SST (09631-00050) of set [09630-00010]

2. Turn the worm shaft to check the turning condition.

Fig. 8-398

Fig. 8-398

3. Loosen the adjusting plug with SST to •adjust the preload.

SST (09631-00050) of set [09630-00010]

Fig. 8-399

Fig. 8-399

4. Insert SST into the serrated section of the worm shaft, and measure the preload with a torque meter. SST [09616-00010]

Preload (starting):

Hold the power piston nut to prevent it from turning.

Fig. 8-400

Fig. 8-400

Tighten the lock nut with SST. SST (09631-00050) of set [09630-00010] (09631-00040) of set [09630-00010] Tightening torque:

Fig. 8-401

6. Recheck the preload.

Check to see that both the right and left rotations are identical SST [09616-00010]

Fig. 8-403

Wrap vinyl tape around the spline area of the cross shaft and loosen the adjusting screw fully.

Fig. 8-403

Fig. 8-404

Align the cross shaft gear center with that of the power piston nut gear.

Fig. 8-405

0 Never turn the cross shaft, as this may cause 0 ring damage.

Tighten the end cover diagonally and evenly in two or three rotations.

Fig. 8-406

Fig. 8-406

Adjust the cross shaft preload. 1. Set worm shaft to midpoint position. Determine total number of the worm shaft turns and return from full lock by half that number.

Fig. 8-407

Fig. 8-407

Fig. 8-408

Insert SST into the serrated section of the worm shaft.

Turn the adjusting screw, and measure preload with a torque meter. SST [09616-00010]

Preload (starting):

Worm shaft preload plus 2-3 kg-cm (1.8 - 2.6 in.-lb)

Use a new seal washer.

Fig. 8-409

Fig. 8-409

4. Tighten the lock nut.

4. Tighten the lock nut.

Fig. 8-410

5. Recheck the preload.

Check to see that both the right and left rotations are identical. SST [09616-00010]

Fig. 8-411

Stake at three points.

INSTALLATION

Install the parts in the numerical order shown in the figure.

Fig. 8-412

8-427

8-427

Fig. 8-413

Fig. 8-413

Fig. 8-419

Gear Housing Pitman Arm

Intermediate Shaft Yoke or Main Shaft Coupling Fluid Pressure House & Fluid Return Hose

Dust Cover or Heat Insulator Dust Cover

Fig. 8-413

Fig. 8-413

Tighten the gear housing set bolts and nuts. Tightening torque: 5.5 - 8.8 kg-m (40 - 63 ft-lb)

Fig. 8-415

Fig. 8-415

Align the matchmarks on the pitman arm and the cross shaft.

Fig. 8-416

Align the matchmarks on the pitman arm and the cross shaft.

Fig. 8-416

0 Align the matchmarks on the pitman arm and the cross shaft.

Fig. 8-417

Fig. 8-417

Tighten the pitman arm set nut. Tightening torque: 16.5 - 19.5 kg-m (120 - 141 ft-lb)

Fig. 8-418

Fig. 8-418

Tighten the pitman arm set nut. Tightening torque: 16.5 - 19.5 kg-m (120 - 141 ft-lb)

Fig. 8-419

Fig. 8-419

Tighten the coupling set bolt.

Fig. 8-420

Install the steering column tube.

Fig. 8-423

Connect the pressure hose with SST. SST [09631-22020]

Connect the pressure hose with SST. SST [09631-22020]

Tightening torque: 4.0 - 5.0 kg-m (29 - 36 ft-lb) Connect the return pipe with SST. SST [09631-22020]

Fig. 8-423

Fig. 8-424

Connect the return hose with SST. SST [09631-22020]

Fig. 8-424

0 Connect the relay rod.

Fig. 8-425

Fill with fluid.

Fluid: ATF type Dexron

Capacity: Gear housing 330 cc

Fig. 8-425

Bleed the system.

Boost the fluid pressure to check for fluid leakage.

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