Corolla Sedan L4-96.8 1587cc 1.6L DOHC (4A-FE) (1989)
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Fig. 9 Exploded View Of Power Steering Gear. Corolla w/Koyo Gear
1.
Remove right and left turn pressure lines, Fig. 9.
2.
Mount steering gear housing in soft jawed vise.
3.
Remove tie rod ends.
4.
Remove clips, clamps and rack boots.
5.
Remove rack ends and claw washers.
6.
Using suitable tool, remove rack guide spring cap locknut.
7.
Using suitable tool, remove rack guide spring cap.
8.
Remove rack guide spring, rack guide, and seat.
9.
Remove dust cover.
10.
Remove rack housing cap.
11.
Using suitable tool, remove self-locking nut. Remove lower bearing and spacer.
12.
Using suitable snap ring pliers, remove snap ring.
13.
Using suitable tool, remove control valve with upper bearing and oil seal. Do not attempt to tap control valve out, since damage to valve will
result.
14.
Using snap ring pliers, remove snap ring. Remove cylinder end stop and spacer.
15.
Temporarily install rack end and tie rod on rack. The following step will damage the cylinder oil seal. Seal will require replacement.
16.
Pull rack out with oil seal.
17.
Remove cylinder oil seal with spacer using suitable tools.
Toyota Type
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 teeth for wear or damage.
2.
Ensure rack runout does not exceed .012 inch (.3mm).
3.
On 1989-90 models, using suitable micrometer and cylinder gauge, measure oil clearance of shaft and bushing. Standard clearance is .0008-.0033
inch (.005-.119 mm). Maximum clearance is .0049 inch (.125 mm).
4.
On 1991 models, Using suitable micrometer and cylinder gauge, measure shaft O.D. and bushing I.D., shaft O.D. should be 1.0925 inch and
bushing I.D. should be 1.1102 inch.
5.
On all models, if necessary, replace control valve, bearing, and oil seal as follows:
a. Remove snap ring and oil seal.
b. Using suitable tools and a press, remove bearing.
c. Using suitable tool, press in new bearing.
d. Using socket and press, install new oil seal.
e. Using snap ring pliers, install snap ring.
6.
If necessary, replace pinion bearing as follows: