Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Power Steering Gear

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REMOVAL & INSTALLATION



Pick-Up and 4Runner
1989-95 2WD MODELS
  1. Drain the power steering fluid.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the reservoir tank.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the Progressive Power Steering (PPS) solenoid connector.
  10.  
  11. Disconnect the intermediate No. 2 shaft.
  12.  
  13. Remove the bolt and spring washer from the Pitman arm. Using SST 09610-55012 or equivalent, disconnect the Pitman arm from the gear housing.
  14.  
  15. Using SST 09631-22020 or equivalent, disconnect the pressure feed tube and the return tube from the gear housing.
  16.  
  17. Remove the union bolt, gaskets, and the return tube from the gear housing.
  18.  

To install:
  1. Connect the pressure feed tube and tighten it to 26 ft. lbs. (36 Nm).
  2.  
  3. Connect the return tube and tighten it to 30 ft. lbs. (41 Nm).
  4.  
  5. Tighten the union bolt with a new gasket on each side of the return tube to 34 ft. lbs. (47 Nm).
  6.  
  7. Align the alignment marks on the Pitman arm and the cross shaft, and install the spring washer and nut. Tighten the nut to 130 ft. lbs. (177 Nm).
  8.  
  9. Connect the intermediate No. 2 shaft to the steering gear.
  10.  
  11. Install the Progressive Power Steering (PPS) solenoid connector.
  12.  
  13. Install the air cleaner assembly.
  14.  
  15. Install the reservoir tank.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Refill and bleed the power steering system.
  20.  

1989-95 4WD MODELS

  1. Drain the power steering fluid.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the reservoir tank.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Disconnect the intermediate No. 2 shaft from the steering gear.
  10.  
  11. Remove the set nut from the Pitman arm. Using SST 09628-62011, or equivalent, disconnect the Pitman arm from the gear housing.
  12.  
  13. Using SST 09631-22020, or equivalent, disconnect the pressure feed tube and the return tube from the gear housing.
  14.  

To install:
  1. Connect the pressure feed tube and tighten it to 26 ft. lbs. (36 Nm).
  2.  
  3. Connect the return tube and tighten it to 30 ft. lbs. (41 Nm).
  4.  
  5. Align the alignment marks on the Pitman arm and the cross shaft. Install the spring washer and nut; tighten it to 130 ft. lbs. (177 Nm).
  6.  
  7. Connect the intermediate No. 2 shaft to the steering gear.
  8.  
  9. Install the air cleaner assembly.
  10.  
  11. Install the reservoir tank.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Refill and bleed the power steering system.
  16.  

1996 4WD MODELS

  1. Place the front wheels facing straight ahead.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the steering wheel pad.
  6.  
  7. Remove the steering wheel.
  8.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the engine under cover.
  4.  
  5. Remove the stabilizer bar.
  6.  
  7. Disconnect the right and left tie rod ends from the steering knuckle.
  8.  
  9. Disconnect the intermediate No. 2 shaft from the steering rack.
  10.  
  11. Disconnect the pressure feed tube and return tube.
  12.  
  13. Remove the power steering rack assembly.
  14.  
  15. Remove the bracket and grommet.
  16.  

To install:
  1. Install the bracket and grommet.
  2.  
  3. Install the power steering rack assembly then tighten the bolts to:

    Rack assembly bolt: 123 ft. lbs. (167 Nm)
     
    Rack assembly nut and bolt: 141 ft. lbs. (191 Nm)
     
    Nut and bolt to the bracket: 123 ft. lbs. (167 Nm)
     

  4.  
  5. Connect the pressure feed tube and the return tube. Tighten to 29 ft. lbs. (40 Nm).
  6.  
  7. Connect the intermediate No. 2 shaft to the steering rack.
  8.  
  9. Connect the right and left tie rod ends to the steering knuckle.
  10.  
  11. Attach the stabilizer bar.
  12.  
  13. Position the front wheels facing straight ahead. Do this with the front of the vehicle jacked up.
  14.  
  15. Center the spiral cable.
  16.  
  17. Install the steering wheel, align the matchmarks on the wheel and column mainshaft.
  18.  
  19. Bleed the power steering system.
  20.  
  21. Check the steering wheel center point.
  22.  
  23. Tighten the steering wheel set nut to 25 ft. lbs. (34 Nm).
  24.  
  25. Install the steering wheel pad.
  26.  
  27. Install the engine under covers.
  28.  
  29. Lower the vehicle.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Check the front end alignment.
  34.  

Tacoma
2WD MODELS

See Figure 1

  1. Place the front wheels facing straight ahead.
  2.  
  3. Disconnect the negative battery cable.
  4.  

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect the right and left tie rod ends from the knuckle.
  4.  
  5. Disconnect the intermediate No. 2 shaft from the steering rack.
  6.  
  7. Using SST 09631-22020 or equivalent, remove the pressure feed and the return tubes.
  8.  
  9. Remove the power steering rack.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the power steering gear-Tacoma 2WD

To install:
  1. Install the power steering rack, then tighten the bolts to 148 ft. lbs. (201 Nm).
  2.  
  3. Install a new O-ring and install the pressure feed tube, then tighten to 33 ft. lbs. (45 Nm). Install the return tube, then tighten to 36 ft. lbs. (49 Nm).
  4.  
  5. Connect the intermediate No. 2 shaft to the steering rack.
  6.  
  7. Connect the right and left tie rod ends to the steering knuckle. Tighten the castle nuts to specification and install new cotter pins.
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Check the steering wheel center point.
  14.  
  15. Bleed the power steering system.
  16.  
  17. Check the front wheel alignment. Tighten the tie rod end locknuts to 67 ft. lbs. (90 Nm)
  18.  

4WD MODELS

See Figure 2

  1. Place the front wheels facing straight ahead.
  2.  
  3. Disconnect the negative battery cable.
  4.  

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the engine under cover.
  4.  
  5. Disconnect the right and left tie rod ends from the steering knuckle.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the power steering gear-Tacoma 4WD

  1. Disconnect the intermediate No. 2 shaft from the steering rack.
  2.  
  3. Disconnect the pressure feed tube and return tube.
  4.  
  5. Remove the power steering rack assembly.
  6.  
  7. Remove the bracket and grommet.
  8.  

To install:
  1. Install the bracket and grommet.
  2.  
  3. Install the power steering rack assembly then tighten the bolts to:

    Rack assembly bolt: 123 ft. lbs. (167 Nm)
     
    Rack assembly nut and bolt: 141 ft. lbs. (191 Nm)
     
    Nut and bolt to the bracket: 123 ft. lbs. (167 Nm)
     

  4.  
  5. Connect the pressure feed tube and the return tube. Tighten to 29 ft. lbs. (40 Nm).
  6.  
  7. Connect the intermediate No. 2 shaft to the steering rack.
  8.  
  9. Connect the right and left tie rod ends to the steering knuckle.
  10.  
  11. Install the engine under covers.
  12.  
  13. Lower the vehicle.
  14.  
  15. Check the steering wheel center point.
  16.  
  17. Bleed the power steering system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Check the front end alignment.
  22.  

T100
2WD MODELS

See Figure 3

  1. Position the front wheels facing straight ahead.
  2.  
  3. Secure the steering wheel so that it does not turn. The driver's seat belt can be used to secure the steering wheel.
  4.  
  5. Place matchmarks on the intermediate shaft and control valve shaft. Remove the lower and upper joint bolts from the intermediate shaft. Disconnect the shaft.
  6.  
  7. Remove the cotter pin and nut from the tie rod ends. Disconnect the tie rod ends using a separator tool.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the power steering gear-T100 2WD

  1. Disconnect the pressure and return pipes using flare nut wrenches.
  2.  
  3. Remove the bracket bolts and grommets.
  4.  
  5. Remove the steering rack assembly from the vehicle.
  6.  

To install:
  1. Install the gear housing then tighten the mounting bolts to 65 ft. lbs. (88 Nm).
  2.  
  3. Install the pressure and return tubes using new O-rings. Tighten the fittings to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the intermediate shaft. Install the lower and upper joint bolts. Tighten the bolts to 26 ft. lbs. (35 Nm).
  6.  
  7. Connect the tie rod ends, tighten to 67 ft. lbs. (90 Nm) and install a new cotter pin.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Fill and bleed the steering system.
  12.  
  13. Check and adjust toe-in.
  14.  

4WD MODELS

See Figure 4

  1. Place the front wheels facing straight ahead.
  2.  
  3. Drain the power steering fluid.
  4.  
  5. Disconnect the negative battery cable.
  6.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.

  1. Raise and safely support the vehicle.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the power steering gear-T100 4WD

  1. Remove the Pitman arm set nut and the spring washer. Using SST 09628-62011, or equivalent, disconnect the Pitman arm from the gear assembly.
  2.  
  3. Disconnect the pressure feed tube and return tube.
  4.  
  5. Make matchmarks and disconnect the intermediate shaft from the steering gear.
  6.  
  7. Remove the power steering gear mounting bolts and remove the gear assembly.
  8.  

To install:
  1. Install the power steering gear assembly, then tighten the bolts to 105 ft. lbs. (142 Nm).
  2.  
  3. Align the matchmarks and connect the intermediate shaft to the steering gear.
  4.  

If installing a new gear assembly, be sure the gear box and the steering wheel are centered.

  1. Connect the pressure feed tube and the return tube. Tighten the line fittings to 26 ft. lbs. (36 Nm).
  2.  
  3. Align the alignment marks on the cross shaft and the Pitman arm and connect the Pitman arm. Install the spring washer and the Pitman arm set nut, then tighten to 130 ft. lbs. (177 Nm).
  4.  
  5. Lower the vehicle.
  6.  
  7. Check the steering wheel center point.
  8.  
  9. Fill and bleed the power steering system.
  10.  
  11. Connect the negative battery cable.
  12.  

Land Cruiser
  1. Drain the power steering fluid.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) battery cable is disconnected.

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the frame seal.
  4.  
  5. Remove the link joint protector.
  6.  
  7. Remove the Pitman arm set nut and spring washer. Using SST 09628-62011, or equivalent, disconnect the Pitman arm from the gear assembly.
  8.  
  9. Using SST 09631-22020, or equivalent, disconnect the pressure feed and the return tubes.
  10.  
  11. Separate the sliding yoke sub-assembly from the steering gear.
  12.  
  13. Remove the mounting bolts and the power steering gear assembly.
  14.  

To install:
  1. Install the power steering gear assembly, then tighten the bolts to 105 ft. lbs. (142 Nm).
  2.  
  3. Connect the sliding yoke sub-assembly to the steering gear.
  4.  
  5. Connect the pressure feed and the return tubes. Tighten the tube fittings to 26 ft. lbs. (36 Nm).
  6.  
  7. Connect the Pitman arm and align the alignment marks on the cross shaft and the Pitman arm. Install the spring washer and the Pitman arm set nut. Tighten the nut to 130 ft. lbs. (177 Nm).
  8.  
  9. Refill and bleed the power steering system.
  10.  
  11. Install the link joint protector.
  12.  
  13. Install the frame seal.
  14.  
  15. Lower the vehicle.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Test drive the vehicle. Check the steering wheel center point.
  20.  

 
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