Power Steering Gear: Disassembly

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

REMOVE 2 TURN PRESSURE TUBES
Using SST, remove the 2 turn pressure tubes.
1. SST 09023-38200
Fig 1: Removing 2 Turn Pressure Tubes Using SST
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SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the PS gear assembly in a vise.
1. SST 09612-00012
Fig 2: Securing PS Gear Assembly In Vise Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS
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: Identifying Matchmarks On Tie Rod End, Lock Nut & Rack End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
1. Using pliers, loosen the clamp as shown in Fig 4 .
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 Rack Boot Clamp Using Pliers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH RACK ENDS AND CLAW WASHERS
1. Using a screwdriver and a hammer, unstake the washer.
  NOTE: Avoid any impact on the steering rack.
  
  Fig 5: Unstaking Washer Using Screwdriver & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a spanner, 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 Fig 6 .
  
  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 Using Spanner & SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the rack guide spring cap lock nut.
1. SST 09922-10010
NOTE: Use SST 09922-10010 in the direction shown in Fig 7 .
REMOVE RACK GUIDE SPRING CAP, CONICAL SPRING, RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
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.
REMOVE DUST COVER
REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
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: Removing Control Valve Housing With Control Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BEARING GUIDE NUT AND CONTROL VALVE ASSEMBLY
1. Using SST, loosen the bearing guide nut.
  1. SST 09631-20060
  Fig 9: Loosening Bearing Guide Nut Using SST
  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.
  
  Fig 10: Tapping Out Control Valve Assembly With Bearing Guide Nut From Control Valve Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
REMOVE CYLINDER END STOPPER AND SPACER
1. Using SST, remove the cylinder end stopper.
  1. SST 09631-20090
Remove the O-ring from the cylinder end stopper.
REMOVE STEERING RACK WITH OIL SEAL
1. Using SST, press out the steering rack with the oil seal.
  1. SST 09950-70010 (09951-07200)
  NOTE: Take care not to drop the steering rack.
Remove the oil seal from the steering rack.

Fig 12: Removing Steering Rack With Oil Seal Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL SEAL
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.
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)
  
  Fig 14: Inserting SST Into Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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 (09612-07220)
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)
  
  Fig 16: Inserting Tip Of SST (09612-07230) In Service Hole Of SST (09612-07130)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
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)
  
  NOTE: Do not damage the rack housing.
  
  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) & Remove Oil Seal Using Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002