Corolla Sport Coupe L4-1587cc 1.6L DOHC (4A-F) (1988)
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c. Reheat rack housing to over 176°F (80°C).
d. Using service tool 09620-30010, install new lower bearing taking care to note correct bearing direction.
6.
If necessary, replace rack bushing as follows:
a. Using service tool 09612-24012, remove rack bushing.
b. Check that tube hole is not blocked with grease.
c. Install new rack bushing using service tool 09612-24012. Press new bushing in until edge surface of rack tube is even with surface of service
tool.
7.
If necessary, replace pinion oil seal as follows:
a. Using service tools 09620-30010 and 09630-24013 or equivalents, remove pinion oil seal.
b. Using service tools used above, drive new pinion seal in so it protrudes .020 inch (.5 mm). During remaining assembly, coat all friction
surfaces with molybdenum disulfide lithium based grease.
8.
Install rack into housing from pinion side. Position notched portion of rack so that pinion can be positioned inside.
9.
Line up cutout portion of rack with pinion and install pinion making sure that pinion end is securely positioned in lower bearing.
10.
Apply liquid sealer to threads of pinion bearing adjusting screw. Install screw using tool 09612-24012 or equivalent.
11.
Line up cutout portion or rack with pinion.
12.
Using service tool used previously, tighten pinion bearing adjusting screw so pinion turning torque is 3.2 inch lbs. (3.7 kg-cm).
13.
Loosen pinion bearing adjusting screw until pinion turning torque is 2-2.9 inch lbs. (2.3-3.3 kg-cm).
14.
Apply liquid sealer to pinion bearing adjusting screw locknut and install locknut. Using tools 09612-10092 and 09612-24012 torque locknut to 83
ft. lbs. (113 Nm). Recheck pinion preload and adjust, if necessary.
15.
Install rack guide with spacer and spring.
16.
Apply liquid sealer to guide spring cap threads.
17.
Mesh rack with pinion and install rack guide spring cap using tool 09612-24012 or equivalent.
18.
Count total number of pinion rotations possible and return pinion half that amount to position pinion in neutral position.
19.
Adjust total preload as follows:
a. Torque rack guide spring cap to 18 ft. lbs. (25 Nm).
b. Return rack guide spring cap 25°.
c. Measure total preload within one rotation from neutral position in both directions. Preload should be 6.9-11.3 inch lbs.
d. If preload is insufficient, retorque guide spring cap and return slightly less than 12°.
e. If preload is excessive, return rack guide spring cap slightly.
20.
Apply liquid sealer on locknut thread and racking housing surface. Install locknut and torque to 51 ft. lbs. (69 Nm).
21.
Recheck total preload. Adjust, if necessary.
22.
Install dust cover.
23.
Install claw washers and rack ends. Torque rack end to 61 ft. lbs. (83 Nm) using tool 09612-10092 and 09612-24012 or equivalents. Stake claw
washer.
24.
Install rack boots taking care not to damage or twist boots. Note difference between right and left boots.
25.
Install clamps and clips with open ends facing outward to avoid damage to boots.
26.
Install tie rod ends so marks are aligned. Adjust toe-in and torque locknuts to 35 ft. lbs. on MR2, or 41 ft. lbs. on Corolla FWD.
Rack & Pinion Power Steering Gear
