Power Steering Gear: Disassembly

1. Using SST, remove the 2 turn pressure tubes.
   1. SST 09023 -38200
2. Remove the 4 O-rings from the 2 turn pressure tubes.
   Fig 1: Using SST, Disconnect Pressure Feed And Return Tubes

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Using SST, secure the PS gear assembly in a vise.

1. SST 09612-00012

Fig 2: Using SST, secure PS gear assembly in a vise

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1. Place matchmarks on the tie rod end and rack end.
2. Loosen the lack nut, and remove the tie rod end and lock nut:
3. Employ the same manner described above to the other side.
   Fig 3: Identifying Matchmarks On The Tie Rod End And Rack End

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1. Using a screwdriver, loosen the clamp.
2. Remove the clamp, clip and rack boot.
   NOTE: Be careful not to damage the boot.

   HINT

   Mark the RH and LH boots.

3. Employ the same manner described above to the other side.
   Fig 4: Using A Screwdriver, Loosen The Clamp

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1. Using a screwdriver and a hammer, unstake the claw washer.
   NOTE: Avoid any impact to the steering rack.
   Fig 5: Using A Screwdriver And A Hammer, Unstake The Claw Washer

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2. Using a spanner (24 mm), hold the steering rack steadily and using SST, remove the rack end.
   1. SST 09922-10010
   NOTE: Use SST 09922-10010 in the direction shown in the illustration.

   HINT:

   Mark the RH and LH rack ends.

3. Remove the claw washer.
4. Employ the same manner described above to the other side.
   Fig 6: Using A Spanner (24 mm), Hold Steering Rack Steadily And Using SST, Remove Rack End

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Using SST, remove the rack guide spring cap lock nut.

1. SST 09922-10010

Fig 7: Using SST, Remove Rack Guide Spring Cap Lock Nut

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1. Using SST, remove the rack guide spring cap. SST 09631-10021
2. Remove the rack guide spring and rack guide sub-assembly.

Using SST, stop the control valve shaft rotating and remove the self-locking nut.

1. SST 09616-00011

1. Place matchmarks on the control valve housing and rack housing.
2. Remove the 2 bolts and pull out control valve housing with control valve assembly.
3. Remove the gasket from the rack housing.
   Fig 10: Placing Match Marks On Control Valve Housing And Rack Housing

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1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve assembly.
2. Press out the control valve assembly with the oil seal.
   NOTE:

   • Place a shop rag between the valve housing and the blocks.
   • Be careful not to drop the valve assembly.
   • Be careful not to damage the oil seal lip.
   Fig 11: Removing Control Valve Assembly

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Remove the oil seal from the control valve assembly.

1. Place matchmarks on the rack housing No. 2 bracket and rack housing.
   Fig 12: Placing Match Marks On Rack Housing No. 2 Bracket And Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, pry the clamp of the rack housing No. 2 bracket and remove the rack housing No. 2 bracket.
3. Remove the rack housing No. 2 grommet from the rack housing No. 2 bracket.
   Fig 13: Using A Screwdriver, Pry Clamp Of Rack Housing No. 2 Bracket

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1. Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
   1. SST 09631-10021
2. Using SST, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.
   1. SST 09631-10021
   Fig 14: Using SST, Turn Cylinder End Stopper Counterclockwise

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1. Using a brass bar and a hammer, tap out the steering rack with the bushing.
2. Remove the bushing from the steering rack.
3. Remove the O-ring from the bushing.
   Fig 15: Removing Steering Rack And Bushing

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Using SST, press out the oil seal.

1. SST 09950-60010 (09951-00290), 09950-70010 (09951-07360)

Fig 16: Using SST, Press Out Oil Seal

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