Power Steering Rack Overhaul Procedure
Group: 07
No.: 06
Date: Sept 08
Camry ACV40, Aurion GSV40
Power Steering Rack Overhaul Procedure
A revised overhaul procedure has been developed for the Camry 40 series and Aurion 40 series production model vehicles.
This revised procedure also introduces new SST's and a completely new overhaul parts kit.
Production Date
| Kit Name | Kit Part Number | Vehicle Production |
|---|---|---|
| SST Kit | J49404 | From June 2008 |
| Overhaul Parts Kit | 04445 - 06200 |
Table Caption: This table lists two kits, the SST Kit and the Overhaul Parts Kit, along with their respective part numbers and the vehicle production dates from which they are applicable.
Note: This kit will also service the 36 series Camry and the Avalon vehicles.
Flat Rate Time
The standard overhaul time for this power steering rack is 1.25 hours or 75 minutes.
Contents
POWER STEERING
SST RECOMMENDED TOOLS EQUIPMENT LUBRICANT SSM
POWER STEERING
SERVICE DATA TORQUE SPECIFICATIONS
RACK & PINION POWER STEERING GEAR OVERHAUL
COMPONENTS REPAIR HINT DISASSEMBLY CLEANING & INSPECTION REASSEMBLY
POWER STEERING
| 09023-38200 | Union Nut Wrench (Previously Released) |
|---|---|
| 09612-00012 | Rack & Pinion Steering Rack Housing Stand (Previously Released) |
| 09616-00011 | Steering Worm Bearing Adjusting Socket (Previously Released) |
| 09922-10010 | Adjustable tie-rod wrench (Previously Released) |
| J-49404 | Steering Rack Overhaul Kit |
| (J-36418-7A) | Seal Protector Sleeve |
| (J-46192-1) | Pinion Seal Protector |
| (J-46192-2) | Pinion Ring Sizer |
| (J-46193) | Pinion Seal Installer |
| (J-49330) | Bearing Protector |
Table Caption: This table lists specialized tools for steering system maintenance and repair, including union nut wrenches, rack and pinion steering tools, and a comprehensive steering rack overhaul kit with various protective and installation components.
EQUIPMENT
| Circlip pliers |
|---|
| Torque wrench |
| Vernier callipers |
| Dial indicator |
| Feeler gauge |
| Micrometer |
Table Caption: This table lists various types of specialized tools used for measurement, adjustment, and mechanical work.
LUBRICANT
Power Steering Fluid
Caltex EP Grease C2 (Cream colour)
Adams Shur Stik Multi-purpose Grease (Blue colour)
SSM
Thread-lock adhesive
(J-49490)
Steering Rack Pressure Test Adaptor
Dexron II or III or equivalent
Included in repair kit
Included in repair kit
Loctite 638 or equivalent
POWER STEERING
Service Data
Refer to the repair manual ST02NEQ.
Torque Specifications
| Part tightened | N*m | kgf*cm | ft.*lbf |
|---|---|---|---|
| Adjuster nut x Rack and pinion housing assembly | 10 1 | 102* | 7* |
| Right turn pressure tube x Rack and pinion housing assembly | 11.5 2 | 111 | 9 |
| Left turn pressure tube x Rack and pinion housing assembly | 11.5 2 | 111 | 9 |
| Pinion and valve assembly nut | 30 | 306 | 22 |
Table Caption: This table lists the tightening torque specifications for various components of a rack and pinion steering system, providing values in Newton-meters, kilogram-force centimeters, and foot-pounds. It details the torque required for securing the adjuster nut and pressure tubes to the rack and pinion housing assembly, as well as the nut for the pinion and valve assembly.
1: Initial torque. Then adjust to achieve correct rack to rack bearing clearance
2: With torque wrench with a fulcrum length or 345 mm.
RACK & PINION POWER STEERING GEAR OVERHAUL
COMPONENTS
REPAIR HINT
- TIGHTENING TORQUE WHEN USING TORQUE WRENCH WITH SST OR EXTENSION TOOL
- (a) When tightening a component using a torque wrench combined with a SST or extension tool, the following formula must be used to calculate the correct torque value.
NOTICE:
If this formula is not applied to the specified torque value when using a SST or extension, the value will be excessive and parts will be damaged.
Formula:
T' = L2 / (L1 + L2) x T
| Item | Description | Example |
|---|---|---|
| New torque value | - | T' |
| Specified torque | 13 Nm | T |
| Length of SST or extension | 50 mm | L1 |
| Length of torque wrench | 200 mm | L2 |
Table Caption: This table defines the variables used in the formula T' = L2 / (L1 + L2) x T, which calculates a new torque value (T') based on a specified torque (T), the length of an SST or extension (L1), and the length of a torque wrench (L2). The examples provided are T = 13 Nm, L1 = 50 mm, and L2 = 200 mm.
Example:
T' = 200 / (50 + 200) x 13
(200 / 250 x 13 = 10.4)
T' = 10.4 Nm
DISASSEMBLY
- REMOVE PRESSURE TUBES
- (a) Using SST, remove the left turn and right turn pressure tubes.
- (b) Remove and discard the 2 O-rings from each tube.
- (c) If required, drain any remaining oil from the steering rack.
SST: 09023-38200
- SECURE RACK AND PINION POWER STEERING GEAR ASSEMBLY
- (a) Using the SST, secure the rack and pinion housing in a vice.
SST: 09612-00012 HINT:
- Tape the SST before use.
- Fit the SST onto the pinion end of the housing.
- To prevent damage, do not over-tighten the SST onto the housing.
- If the SST is difficult to install, remove the pressure tubes.
- (b) Using the SST, centre the steering rack within the housing.
- REMOVE STEERING RACK BOOT CLIP (Refer to the repair manual ST02NEQ)
- REMOVE NO. 2 STEERING RACK BOOT CLAMP (Refer to the repair manual ST02NEQ)
- REMOVE NO. 2 STEERING RACK BOOT (Refer to the repair manual ST02NEQ)
- REMOVE NO. 1 STEERING RACK BOOT (Refer to the repair manual ST02NEQ)
- REMOVE STEERING RACK END SUB-ASSEMBLY (Refer to the repair manual ST02NEQ)
- REMOVE RACK BEARING ASSEMBLY
- (a) Remove and discard the sealing plug.
- (b) Using a 19 mm hex socket, remove and discard the adjuster plug, adjuster spring and rack bearing assembly.
SST: 09616-00011
NOTICE:
Thread-locking compound is applied to the adjuster plug during manufacture and the plug will be difficult to remove. Carefully rotate the plug back and forth during removal to avoid damaging the housing thread.
- REMOVE PINION AND VALVE ASSEMBLY
- (a) Remove and discard the spool shaft boot.
- (b) Remove excess grease.
- (c) Remove and discard the retaining ring from the top of the rack and pinion housing.
HINT:
If required, tap the spool shaft seal with a circular punch to assist removal.
- (d) Remove and discard the dust cover from the bottom of the housing.
NOTICE:
The spool shaft
