With Power Steering

Disassembly

Fig. 40 Exploded View Of Power Steering Gear. 4WD Pickup & 1990-92 4Runner:

1. Place gear in suitable soft jawed vise.
2. Remove end cover adjusting screw locknut and seal washer, remove end cover attaching bolts and No. 1 hose support bracket, Fig. 40, screw in adjusting screw until cover is removed.
3. Using suitable plastic hammer, tap out cross shaft end and remove shaft.
4. Using tool No. 09043-38100 or equivalent, remove plunger guide nut, then remove spring, plunger, plunger guide and O-ring.
5. Remove four valve body cap bolts, then using tool No. 09616-00010 or equivalent, turn shaft clockwise to disconnect worm gear valve body from gear housing.
6. Hold power piston so it cannot move, turn wormshaft clockwise, then remove valve body and power piston assembly and O-ring. Ensure power piston nut does not come off with worm shaft.

Inspection & Repair

1. Place valve body in suitable soft jawed vise, using suitable dial indicator, inspect ball clearance, moving worm gear up and down, maximum ball clearance should be .00059 inch, if clearance is not as indicated, replace power control valve assembly.
2. Place cross shaft in suitable soft jawed vise, then using suitable dial indicator, measure thrust clearance, .0012-.0020 inch should be indicated, is not as indicated, adjust thrust clearance.
3. Adjust thrust clearance as follows:
a. Using suitable hammer and chisel, remove locknut stake.
b. Using tool No. 09630-00012 or equivalent, loosen locknut.
c. Turn adjusting screw for correct thrust clearance, then tighten locknut.
d. Stake locknut.
4. If required, replace needle roller bearings as follows:
a. Using suitable screw driver, remove oil seal.
b. Using suitable snap ring pliers, remove snap ring.
c. Remove metal spacer, O-ring and Teflon ring.
d. Using tool No. 09630-00012 or equivalent, press out bearings.
e. Install new lower bearing, ensuring it is positioned .909 inch away from lower end of housing.
f. Press in new upper bearing, ensuring top end is installed so it aligns with housing end surface.
g. Install O-ring and metal spacer.
h. Using suitable snap ring pliers, install snap ring.
i. Form Teflon ring into heart shape and install with fingers.
j. Using tool No. 09630-00012 or equivalent, form Teflon ring, Teflon ring must be formed before sector shaft installation or damage may occur.
h. Drive in new oil seal.
5. If required, replace control valve Teflon rings as follows:
a. Using suitable screwdriver, remove Teflon ring and O-ring. Do not damage control valve.
b. Install new O-ring.
c. Expand Teflon ring by hand, do not over expand Teflon ring.
d. Install Teflon ring.
e. Coat Teflon ring with power steering fluid and snug down with piston ring compressor for 5-7 minutes.
6. If required, replace union set as follows:
a. Using suitable screw extractor, remove union seat.
b. Using suitable plastic hammer and extension bar, tap in new union seat.

Assembly

1. Install O-rings to gear housing and valve body, mount gear housing to tool No. 09630-00012 or equivalent, then install tool to suitable soft jawed vise. Install worm gear valve body. Do not damage Teflon ring.
2. Hold power piston nut to prevent turning, then using tool No. 09616-00010 or equivalent, check worm gear preload, starting preload should be 2.6-4.8 inch lbs. If preload is not as indicated, replace worm gear assembly.
3. Install plunger, plunger guide and spring.
4. Install plunger guide nut O-ring, then using tool No. 09043-38100 or equivalent, install plunger guide nut and tighten specifications.
5. Install end cover O-ring, fully loosen adjusting screw, using suitable screwdriver, assemble cross shaft to end cover.
6. Set worm gear at center of gear housing.
7. Install and push cross shaft into gear housing so center teeth mesh together, install four cap bolts tightening to specifications in diagonal pattern.
8. Using tool No. 09616-00010 or equivalent, turn worm shaft to full lock in both directions to determine exact center, place matchmarks on worm shaft and housing to show neutral position.
9. Install tool No. 09616-0010 or equivalent with suitable torque meter to worm shaft, turn adjusting screw while measuring preload, total starting preload should be 4.3-8.3 inch lbs.
10. Install washer, then install and tighten locknut while holding adjusting screw.
11. Recheck total preload.