Power Steering Gear: Disassembly

CAUTION: When using a vise, do not overtighten it.

Remove 2 turn pressure tubes.
1. Remove the tube clamp.
2. Using SST, disconnect the 2 turn pressure tubes.
  
  Fig 1: Disconnecting 2 Turn Pressure Tubes With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and 2 turn pressure tubes.
  1. SST 09023-38200
Secure PS gear assembly in vise.
1. Using SST, secure the PS gear assembly in a vise.
  
  Fig 2: Securing PS Gear Assembly In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. SST 09612-00012
Remove pressure control valve.
1. Using a hexagon wrench (6 mm), remove the 3 bolts and pressure control valve.
  
  Fig 3: Locating Bolts For Removal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 O-rings from the pressure control valve.
Remove RH and LH tie rod ends and lock nuts.
1. Place matchmarks on the tie rod end and rack end.
  
  Fig 4: Identifying Matchmarks On Tie Rod & Rack End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the lock nut and remove the tie rod end and lock nut.
3. Employ the same manner described above to the other side.
Remove RH and LH clips, rack boots and clamps.
1. Using needle nose pliers, loosen the wire.
2. Remove the clip and rack boot.
  CAUTION: Be careful not to damage the boot.
  
  NOTE: Mark the RH and LH rack boots.
3. Employ the same manner described above to the other side.
Remove RH and LH rack ends and claw washers.
1. Using a screwdriver and a hammer, remove the claw washer.
  
  Fig 5: Removing Claw Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Avoid any impact on the steering rack.
2. Using a wrench, hold the steering rack steady and using SST, remove the rack end.
  1. SST 09922-10010
  NOTE:
  - Use SST 09922-10010 in the direction shown in Fig 6.
    
    Fig 6: Removing Rack End With SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Mark the RH and LH rack ends.
3. Remove the claw washer.
4. Employ the same manner described above to the other side.
Remove rack guide spring cap lock nut.
1. Using SST, remove the rack guide spring cap lock nut. See Fig 7.
2. SST 09922-10010
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
Remove rack guide spring cap, rack guide spring, rack guide sub-assembly.
1. Using a hexagon wrench (24 mm), remove the rack guide spring cap.
2. Remove the rack guide spring and rack guide sub-assembly.
Remove rack housing cap.
Remove self-locking nut.
1. Using SST, stop the control valve shaft rotating and remove the self-locking nut.
  
  Fig 8: Removing Self-Locking Nut With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09616-00011
Remove dust cover.
Remove control valve housing with control valve assembly.
1. Using a hexagon wrench (6 mm), remove the 2 bolts.
2. Pull out the control valve housing with control valve assembly.
3. Remove the O-ring from the valve housing.
Remove control valve assembly.
1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
2. Using a plastic hammer, tap out the control valve assembly.
  
  Fig 9: Tapping Control Valve Assembly With Plastic Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove bearing and spacer.
1. Remove the bearing and spacer from the rack housing.
Remove cylinder end stopper, oil seal and steering rack.
1. Using snap ring pliers, remove the snap ring from the rack housing.
2. Using a brass bar, press the steering rack until the cylinder end stopper slightly touches the press block.
  
  Fig 10: Removing Cylinder End Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull out the steering rack with the cylinder end stopper and oil seal.
  NOTE: If necessary, slightly tap the rack end with a brass bar and a hammer.
Remove oil seal.
1. Using SST, press out the oil seal.
  
  Fig 11: Removing Oil Seal With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-60010 (09951-00310), 09950-70010 (09951-07360)