Power Steering Gear: Disassembly

SST 09023-38200

1. REMOVE TURN PRESSURE TUBES 

   Using SST, remove the 2 turn pressure tubes.

   Fig 1: Removing Turn Pressure Tubes Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. SECURE PS GEAR ASSEMBLY IN VISE 

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

   Fig 2: Securing PS Gear Assembly In A Vise Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09612-00012

3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS 
   1. Place matchmarks on the tie rod end and rack end.
   Fig 3: Identifying Matchmarks Of Tie Rod 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.
   NOTE: Mark the RH and LH tie rod ends and lock nuts.
4. REMOVE RH AND LH CLIPS, CLAMPS AND RACK BOOTS 
   1. Loosen the clamp screw.
   2. Remove the clip, clamp and rack boot.
      NOTE: Be careful not to damage the boot.
   3. Employ the same manner described above to the other side.
   NOTE: Mark the RH and LH rack boots.
5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS 
   1. Using a screwdriver and a hammer, unstake the claw washer.
      Fig 4: Unstaking Claw Washer Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Avoid any impact on the steering rack.
   2. Using a spanner (22 mm), hold the steering rack steadily and using SST, remove the rack end.
      Fig 5: Removing The Rack End Using SST

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09922-10010
      NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   3. Remove the claw washer.
   4. Employ the same manner described above to the other side.
   NOTE: Mark the RH and LH rack ends.
6. REMOVE NO. 1 RACK HOUSING BRACKET AND GROMMET 
   1. Place matchmarks on the No. 1 rack housing bracket and rack housing.
   Fig 6: Placing Matchmarks On Rack Housing Bracket & Rack Housing
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the bolt and bracket.
   3. Remove the grommet from the bracket.
7. 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 the illustration.
8. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, CONICAL SPRING AND RACK GUIDE 
   1. Using a hexagon wrench (21 mm), remove the rack guide spring cap.
   Fig 7: Removing Rack Guide Spring, Conical Spring & Rack Guide Using A Hexagon Wrench
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the rack guide spring, conical spring and rack guide.
9. REMOVE RACK HOUSING CAP 
10. REMOVE SELF-LOCKING NUT 

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

    Fig 8: Removing Self-Locking Nut Using SST

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. SST 09616-0001 1
11. REMOVE CONTROL VALVE ASSEMBLY, UPPER OIL SEAL AND UPPER BEARING 
    1. Using snap ring pliers, remove the snap ring from the rack housing.
    Fig 9: Removing Snap Ring From Rack Housing Using Pliers
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the control valve assembly with the oil seal and upper bearing.
       1. SST 09613-12010
       NOTE: Never attempt to tap out the control valve as this would damage it.
    3. Remove the oil seal and bearing from the control valve assembly.
12. REMOVE CYLINDER END STOPPER 
    1. Using snap ring pliers, remove the snap ring from the rack housing.
    2. Remove the cylinder end stopper.
13. REMOVE STEERING RACK AND OIL SEAL 
    1. Using a brass bar, press out the steering rack with the oil seal.
    Fig 10: Pressing Out Steering Rack With The Oil Seal Using Brass Bar
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the oil seal from the steering rack.