Corolla RWD L4-1587cc 4A DOHC (1985) Steering Gear Removal and Installation
6.
Using tool 09612-24012 or equivalent, remove locknut and rack guide spring cap.
7.
Remove rack guide spring, rack guide and seat.
8.
Remove dust cover.
9.
Using tool 09630-00011 or equivalent, remove locknut and adjusting plug.
10.
Remove control valve bearing, control valve, bearing, plate and Teflon ring.
11.
Remove 3 bolts and control valve housing and O-rings.
12.
Unstake cylinder end stop nut. Using tool 09631-12010 or equivalent, remove cylinder end stop nut.
13.
Remove steering rack with cylinder end stop, O-ring and rack end guide.
Inspection & Assembly
During assembly, coat all moving parts, bearings, and bushings with molybdenum disulfide lithium base grease, and all O-rings and Teflon rings with
power steering fluid.
1.
Check back surface of rack and rack teeth for wear or damage, Fig. 25.
2.
Check that rack run-out does not exceed .012 inch (.3 mm).
3.
Check needle roller bearing for wear or damage. Replace cylinder housing assembly, if necessary.
4.
If necessary, replace adjusting plug oil seal as follows:
a. Remove old oil seal using screwdriver.
b. Using socket wrench, install new oil seal.
5.
If necessary, replace cylinder housing oil seal as follows:
a. Insert tool 09631-12020 into rack guide installation hole and hold in place. Insert 09631-12020 into cylinder housing end. Remove oil seal.
b. Insert tools 09631-12020 and 09631-12040 into oil seal and spacer.
c. Tap spacer and oil seal in through rack end guide.
6.
If necessary, replace Teflon ring and O-ring as follows:
a. Remove Teflon ring and O-ring.
b. Install new O-ring.
c. Carefully stretch new Teflon ring with fingers and install in piston groove of rack.
d. Using fingers snug Teflon ring into groove.
7.
Install tool 09631-16020 on rack.
8.
Coat tool with power steering fluid.
9.
Insert rack into cylinder and remove tool.
10.
Place new O-ring in cylinder end stop.
11.
Wrap suitable tape around rack end and carefully push cylinder end stop on, taking care not to damage oil seal lip.
12.
Using tool 09631-12010 or equivalent, torque stop nut to 127 ft. lbs. (172 Nm). Stake nut.
13.
Check air tightness of cylinder as follows:
a. Attach tool 09631-12050 to cylinder housing fittings.
b. Apply 15.75 inches Hg (400 mm Hg) of vacuum for 30 seconds.
c. Check that vacuum does not drop.
14.
Place new O-rings in valve housing and install valve housing. Torque bolts to 13 ft. lbs. (18 Nm).
15.
Install Teflon ring, plate, bearing, control valve, and bearing.
16.
Install adjusting plug and torque to 7 ft. lbs. (10 Nm) using tool 09630-00011 or equivalent.
17.
Using tool 09616-00010 or equivalent, turning torque at pinion shaft. Preload should be 3.5-5.6 inch lbs. (.4-.6 Nm). Tighten or loosen adjusting
plug to obtain proper preload.
18.
Install adjusting plug locknut and torque to 36 ft. lbs. (49 Nm) using tool 09630-00011 or equivalent. Recheck pinion preload.
19.
Install dust cover.
20.
Adjust total preload as follows:
a. Install seat, rack guide and rack guide spring.
b. Apply liquid sealer to threads of rack guide spring cap.
c. Install rack guide spring cap and torque to 18 ft. lbs. (25 Nm) using tool 09612-24012 or equivalent.
d. Turn spring cap back 30°.
e. Turn pinion shaft and operate steering rack 2 full strokes to seat bearings.
f.
Using tools 09612-24012 and 09616-00010 or equivalents and torque wrench, turn rack guide spring cap until preload is 4.3-8.7 inch lbs.
(.5-1 Nm).
g. Apply liquid sealer to locknut and rack housing contact surfaces.
h. Torque rack guide spring cap locknut to 51 ft. lbs. (69 Nm) using tool 09612-24012.
i.
Recheck total preload, if incorrect, readjust.
21.
Install claw washers and rack ends.
22.
Check that tube hole is not clogged with grease and install rack boots, clamps and clips.
23.
Install tie rod ends and align marks. After adjusting toe-in, torque clamp bolt to 13 ft. lbs. (17 Nm).
24.
Install right and left turn pressure lines. Using tool 09631-22020 torque fittings to 22 ft. lbs. (29 Nm).
