Power Steering Gear: Disassembly

Using SST, remove the 2 turn pressure tubes.

SST 09023-38200

Fig 1: Removing Turn Pressure Tubes

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

SST 09612-00012

Fig 2: Securing PS Gear Assembly In Vise

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place matchmarks on the tie rod end, lock nut and rack end.
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.

Fig 3: Placing Matchmarks On Tie Rod End, Lock Nut And Rack End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using pliers, loosen the clamp as shown in the illustration.
2. Remove the clamp, clip and rack boot.
   NOTE: Be careful not to damage the boot.

   HINT:

   Mark the RH and LH rack boots.

3. Employ the same manner described above to the other side.

Fig 4: Loosening Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver and a hammer, unstake the washer.
   NOTE: Avoid any impact on the steering rack.
   Fig 5: Unstaking Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a spanner, hold the steering rack steadily and using SST, remove the rack end.

   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: Removing Rack End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

SST 09922-10010

1. Using a hexagon wrench (24 mm), remove the rack guide spring cap.
2. Remove the conical spring, rack guide spring and rack guide sub-assembly.

Fig 7: Removing Rack Guide Spring Cap Lock Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place matchmarks on the control valve housing and rack housing.
2. Remove the 2 bolts and pull out the control valve housing with control valve assembly.
3. Remove the O-ring from the control valve housing.

Fig 8: Placing Matchmarks On Control Valve Housing And Rack Housing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, loosen the bearing guide nut.

   SST 09631-20060

   Fig 9: Loosening Bearing Guide Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
3. Using a plastic hammer, tap out the control valve assembly with the bearing guide nut from the control valve housing.
   NOTE: Be careful not to damage the oil seal lip
4. Remove the bearing guide nut from the control valve assembly.
5. Remove the O-ring from the bearing guide nut.

Fig 10: Tapping Out Control Valve Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the cylinder end stopper.

   SST 09631-20090

2. Remove the O-ring from the cylinder end stopper.
3. Remove the spacer.

Fig 11: Removing Cylinder End Stopper

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, press out the steering rack with the oil seal.

   SST 09950-70010 (09951-07200)

   NOTE: Take care not to drop the steering rack.
2. Remove the oil seal from the steering rack.

Fig 12: Pressing Out Steering Rack With Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST (09612-07130) on SST (09612-07210).

   SST 09612-70100 (09612-07130, 09612-07210)

   NOTE:

   • Before using them, apply a small dab of grease to the inside wall of SST (09612-07210, 09612-07130).
   • To prevent the inside of the housing from being damaged securely install SST 09612-07130) on SST (09612-07210).
   Fig 13: Installing SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Diagonally insert SST (09612-07210) into the housing until it contacts with the oil seal, and then further insert the SST (09612-07210) until the tip of SST (09612-07220) contacts with SST (09612-07130).

   SST 09612-70100 (09612-07130, 09612-07210, 09612-07220)

   NOTE: Do not damage the inside of the housing.
   Fig 14: Insert SST (09612-07210) Into Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Secure SST (09612-07220), and pull SST (09612-07210) to place SST (09612-07130) in the housing.

   SST 09612-70100 (09612-07130, 09612-07210, 09612-07220)

   HINT:

   Place SST on the chamfering position between the oil seal and rack housing.

4. Remove the SST (09612-07210, 09612-07220).

   SST 09612-70100 (09612-07210, 09612-07220)

5. After installing SST (09612-07240) on SST (09612-07210), insert the tip of SST (09612-07230) in the service hole of SST (09612-07130).

   SST 09612-70100 (09612-07130, 09612-07230, 09612-07240)

   NOTE:

   • Before using them, apply a small dab of grease to the tip of SST (09612-07230).
   • To prevent SST (09612-07130) from being damaged, be sure to install SST (09612-07240).
   • Do not damage the inside of the rack housing.
   Fig 15: Pulling SST (09612-07210) To Place SST (09612-07130) In Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 16: Inserting Tip Of SST (09612-07230) In Service Hole Of SST (09612-07130)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install SST (09951-07100) on SST (09612-07230) and remove the oil seal using a press.

   SST 09612-70100 (09612-07130, 09612-07230, 09612-07240), 09950-70010 (09951-07100)

HINT:

Replace SST (09951-07100) with SST that is different in length in the set, if necessary.

Fig 17: Installing SST (09951-07100) On SST (09612-07230) And Removing Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002