Removal
When removing and installing the steering gear, refer to the assembly drawing.
1. Remove the front wheel.
2. Drain the power steering fluid.
3. Install the engine support device.
Removing the front steering gear
1 - air filter,
2 - container with activated carbon,
3, 16 - engine support,
4 - steering mechanism,
5 - clamp (4WD with automatic transmission),
6 - cotter pin,
7 - front propeller shaft,
8 - gasket,
9 - exhaust pipe,
10 - engine protection cover,
11 - holder,
12 - longitudinal beam,
13 - control cable (with automatic transmission),
14 - support bracket,
15 - sleeve holder,
17 - cross beam,
18 - bushing,
19 - bracket,
20 - front steering gear propeller shaft (4WS).
4. (Models with 4WS)
Lock the rear steering gear in neutral position.
The full article is posted on the website (Toyotaman.ru)
5. (Models with 4WS)
Remove the rear steering gear propeller shaft.
6. Disconnect the tie rod ends
a) Remove the cotter pins and unscrew the nuts.
b) Using a special tool, disconnect the steering rod ends from the steering knuckle.
7. Remove the engine protection cover.
8. (With automatic transmission)
Loosen the bolts and disconnect the transmission control cable clamps.
9. Loosen the bolts and nuts and remove the cross beam.
Steering mechanism (2WS).
1 - O-ring seal,
2 - oil seal,
3 - Teflon ring,
4 - worm with control valve,
5, 8 - nipple seat,
6 - anther,
7 - worm housing with control valve,
9 - discharge pipeline,
10 - return pipeline,
11 - lock nut,
12 - guide rail cover,
13 - spring,
14 - guide rail seat,
15 - seal,
16 - steering gear housing,
17 - spacer,
18 - oil seal,
19 - lock washer,
20 - steering rod,
21, 30 - steering rod end,
22, 29 - clamp,
23, 28 - case,
24 - retaining ring,
25 - limiting sleeve,
26, 27 - clamp,
31 - oil seal,
32 - O-ring seal,
33 - Teflon ring,
34 - rack,
35 - bearing guide nut,
36 - bearing,
37 - lock nut,
38 - rack guide,
39 - bearing,
40 - oil seal.
Note: when assembling, apply the following to the parts indicated by the arrows:
,
- consistent grease,
- power steering fluid,
- silicone grease,
- sealant.
10. Unscrew the mounting bolts and stabilizer holders and bushings.
11. Loosen the mounting bolts and remove the holder.
12. Loosen the bolts and nuts and remove the longitudinal beam.
13. Loosen the bolts and nut and remove the engine support.
14. Disconnect the return and discharge pipes.
15. Disconnect the intermediate shaft.
a) Loosen the bolt (2) securing the universal joint to the intermediate shaft.
b) Apply alignment marks, unscrew the bolt (1) and disconnect the intermediate shaft with the universal joint from the worm.
16. (4WD)
a) Remove the air filter.
b) Remove the activated carbon container together with the bracket.
c) Remove the left engine mount.
d) Apply alignment marks and disconnect the front propeller shaft.
d) Insert the mandrel as shown in the figure.
17. Unscrew the nuts and bolt and remove the steering gear.
2WD
4WD
18. Unscrew the two nuts and disconnect the automatic transmission control cable clamp.
19. From the gearbox side, lower the power unit by ten centimeters.
Caution: Do not lower too low to prevent the drive shaft from contacting the suspension arm and damaging the boots.
20. Disconnect the steering gear, turn it to the left and remove it as shown in the figure.
Caution: When removing, wrap the steering gear parts that may come into contact with the body with a rag to avoid damaging them.
Front steering gear (4WS).
1, 4 - nipple seat,
2, 11, 19, 32 - boot,
3 - worm housing with control valve,
5 - guide rail,
6 - spring,
7 - guide rail cover,
8, 13, 25 - lock nut,
9 - rear steering gear drive pinion,
10, 28, 31, 36 - bearing,
12 - gear cover,
14, 17 - retaining ring,
15, 20, 37 - oil seal,
16, 26 - spacer,
18 - limiting sleeve,
21 - rail,
22, 33 - ring seal,
23, 35 - Teflon ring,
24 - threaded plug,
27 - lower washer,
29 - upper washer,
30 - steering gear housing,
34 - worm with control valve.
Note: when assembling, apply the following to the parts indicated by the arrows:
,
- consistent grease,
- power steering fluid,
- sealant.
Replacing steering rods
1. Disconnect the tie rod ends from the steering knuckle arms.
2. Loosen the lock nut and unscrew the tie rod end.
3. Remove the steering rod.
a) Loosen the clamps and remove the steering rod boot.
Caution: Be careful not to damage the case.
b) Bend back the bent parts of the lock washer.
Caution: Do not damage the rack.
c) Unscrew the steering rod as shown in the figure. Remove the lock washer.
4. Install the new steering rod.
a) Install a new lock washer.
b) Apply grease to the ball joint of the steering rod (indicated by an arrow in the figure).
c) Install and tighten the steering rod.
- Tightening torque - 85 Nm
d) Using a brass rod and a hammer, bend the lock washer.
Caution: Do not damage the rack.
5. Install the cover and clamps.
a) Make sure that the hole in the rack is not clogged with grease.
Note: If the hole is clogged, the pressure generated inside the cover when turning the steering wheel may damage the cover.
b) Install the cover and clamps Secure the cover with a large clamp.
6. Install the tie rod end.
a) Screw the lock nut and tip onto the steering rod.
- Tightening torque - 75 Nm
c) Make sure that the cover is not twisted and secure it with a small clamp.
7. Connect the tie rod ends to the steering knuckle arms.
Note: After replacing the steering rods, adjust the front wheel alignment.
Installation
1. Install the steering gear assembly.
a) Install washers on each steering gear mounting stud on the right side.
b) Install the steering gear.
c) Install and tighten the steering gear mounting nuts and bolt.
- Tightening torque - 60 Nm
g) (4WD models)
Secure the transmission control cable clamp.
2. (4WD models).
Install the engine mount.
a) Install the engine support and tighten the bolt.
- Tightening torque - 89 Nm
b) Install a container with activated carbon.
- Tightening torque - 7.5 Nm
3. (4WD models).
Install the air filter.
4. (4WD models).
Install the front propeller shaft.
a) Remove the mandrel.
b) Install the front propeller shaft.
Note: Be careful not to damage the seal.
c) Align the alignment marks made during disassembly, install the mounting bolts and tighten them.
- Tightening torque - 75 Nm
5. Connect the intermediate shaft to the worm.
a) Install the intermediate shaft, aligning the marks made during disassembly.
b) Tighten the bolt (1) securing the shaft to the worm.
- Tightening torque - 36 Nm
c) Tighten the bolt (2) securing the shaft to the universal joint.
- Tightening torque - 36 Nm
6. Connect the return and pressure pipes to the steering gear.
- Tightening torque - 45 Nm
Note: Tighten the pipe fittings until the threads are not visible.
7. Install the engine support.
a) Install the engine mount bracket and tighten the mounting bolts.
- Tightening torque - 79 Nm
b) Install the support and tighten the bolt.
- Tightening torque - 89 Nm
8. Install the longitudinal beam and tighten the mounting bolts and nuts.
Tightening torque:
- Bolts A - 62 Nm
- Bolts B - 74 Nm
- Bolts C - 40 Nm
b) Install the holder and tighten the two bolts
- Tightening torque - 21 Nm
9. Install two bushings and two holders on the stabilizer and connect it to the body.
- Tightening torque - 86 Nm
10. Install the cross beam and tighten the mounting bolts and nuts.
Tightening torque:
- Bolts A - 155 Nm
- Bolts B - 74 Nm
- Bolts C - 19 Nm
b) (automatic transmission)
Tighten the transmission control cable bracket mounting bolts.
- Tightening torque - 4 Nm
11. Install the exhaust pipe.
12. Install the lower engine protection cover.
13. Connect the tie rod ends to the steering knuckle arms, tighten the nut and install a new cotter pin.
- Tightening torque - 50 Nm
Note: when installing the cotter pin, the nut can be turned at an angle of no more than 60°.
14. Remove the engine support device.
15. Install the front wheel
- Tightening torque - 105 Nm
16. Make sure the steering wheel is installed correctly.
17. Top up the power steering fluid.
18. Bleed the power steering system.
19. Make sure there are no leaks in the system
20. Check the front wheel steering angles.
21. (4WD models)
Check the transmission oil level.