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Power Steering Gear: Disassembly

NOTE: When using a vise, do not overtighten it.
  1. REMOVE TURN PRESSURE TUBES 

    Using SST, remove the 2 turn pressure tubes. SST 09023-38200

    Fig 1: Removing Turn Pressure Tube Using SST
    G02926262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. SECURE P/S GEAR ASSEMBLY IN VISE 

    Using SST, secure the P/S gear assembly in a vise. SST 09612-00012

    Fig 2: Securing P/S Gear Assembly In Vise Using SST
    G02926263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS 
    1. Place matchmarks on the tie rod end 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.

      HINT:

      Mark the RH and LH tie rod ends and lock nuts.

      Fig 3: Marking RH & LH Tie Rod Ends & Lock Nuts
      G02926264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.

      HINT:

      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
      G02926265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Avoid any impact on the steering rack.
    2. Using SST and spanner (22 mm), remove the power steering rack and claw washer.

      SST 09922-10010

      HINT:

      Using spanner, hold the steering rack to remove the rack end and claw washer.

      Fig 5: Removing Power Steering Rack And Claw Washer Using SST & Spanner
      G02926266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Use SST 09922-10010 in the direction shown in Fig 5.

      HINT:

      Mark the RH and LH rack ends.

    3. Using 2 SST, remove the other rack end.

      HINT:

      Using SST, hold the power steering rack to remove the rack end and claw washer.

  6. REMOVE RACK GUIDE 
    1. Using a straight hexagon wrench 24, remove the rack guide spring cap.
    2. Remove the rack guide spring and rack guide.
  7. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY 
    1. Place matchmarks on the control valve housing and rack housing.
    2. Remove the 2 bolts.
    3. Pull out the control valve housing with control assembly.
    4. Remove the gasket

      SST 09616-00011

      Fig 6: Placing Matchmarks And Removing Control Valve And Rack Housing
      G02926267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CONTROL VALVE ASSEMBLY, UPPER OIL SEAL AND UPPER BEARING 
    1. Wind vinyl tape on the control valve shaft.
    2. Press out the control valve assembly.

      SST 09613-12010

      NOTE:
      • Be careful not to damage the oil seal lip.
      • Place a shop rag between the valve housing and the blocks.
      • Be careful not to drop the valve assembly.
    3. Remove the oil seal and bearing from the control valve assembly.
      Fig 7: Removing Control Valve Assembly, Upper Oil Seal And Upper Bearing
      G02926268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CYLINDER END STOPPER 
    1. Place rack housing in vise.
      NOTE: Hold the arrow part in Fig 8 in a vice.
    2. Using SST, remove the cylinder end stopper from the rack housing.

      SST 09631-20120

      3. Fig 8: Removing Cylinder End Stopper From Rack Housing
      G02926269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, remove the O-ring from the cylinder end stopper.
      NOTE: Do not damage the cylinder end stopper.
    4. Using a screwdriver, remove the rack guide bush from the cylinder end stopper.
      NOTE: Do not damage the cylinder end stopper.
  10. REMOVE POWER STEERING RACK 
    1. Using a service bolt and press, remove the steering rack from the steering rack housing.
      Fig 9: Removing Steering Rack From Steering Rack Housing Using Service Bolt & Press
      G02926270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Recommended service bolt: 

      RECOMMENDED SERVICE BOLT IDENTIFICATION

      Thread diameter 14 mm (0.55 in.)
      Thread pitch 1.5 mm (0.059 in.)
    2. Using a screwdriver, remove the power piston oil seal and power piston O-ring from the steering rack.
      NOTE: Do not damage the steering rack ring groove.
    3. Remove the cylinder end stopper oil seal from the steering rack.
  11. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL 
    1. Using needle nose pliers, remove the bush from the rack housing.
      Fig 10: Removing Bush From Rack Housing
      G02926271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install SST (09612-07130) on SST (09612-07210). SST 09612-70100 (09612-07130, 09612-07210)
      Fig 11: Installing SST
      G02926272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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).
    3. 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)

      Fig 12: Inserting SST Into Housing
      G02926273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not damage the inside of the housing.
    4. 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 13: Securing SST (09612-07220), Pulling SST (09612-07210) To Place SST (09612-07130) In Housing
      G02926274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

    5. Remove the SST (09612-07210, 09612-07220). SST 09612-07100 (09612-07210, 09612-07220)
    6. 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 14: Inserting Tip Of SST (09612-07230) In Service Hole Of SST (09612-07130)
      G02926275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before using them, apply a small dab of grease to the tip of SST (09612-07130).
      • To prevent SST (09612-07130) from being damaged, be sure to install SST (09612-07240).
      • Do not damage the inside of the rack housing.
    7. 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)

      Fig 15: Installing SST (09951-07100) On SST (09612-07230) And Removing Oil Seal
      G02926276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not damage the rack housing.

      HINT:

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

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