Power Steering Gear: Disassembly

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

SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise, as shown in the illustration.

SST 09630-00014 (09631-00142)

Fig 1: Securing Gear Assembly In A Vise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 TURN PRESSURE TUBES
Using SST, remove the tube.

SST 09023-38200

Fig 2: Removing Turn Pressure Tubes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TUBE SUPPORT RETAINER
Remove the bolt.
REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
1. Using pliers, loosen the clamp, as shown in the illustration.
  NOTE: Be careful not to damage the boot.
2. Remove the clip, rack boot and clamp.
3. Employ the same manner described above to the other side.
HINT:

Mark the RH and LH rack boots.

Fig 3: Loosening Clamp On Rack Boot
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH RACK ENDS AND CLAW WASHERS
1. Using a screwdriver and hammer, stake back the washer.
  NOTE: Avoid and impact to the steering rack.
  
  Fig 4: Staking Back Claw Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a spanner to hold the steering rack steady, and using SST, remove the rack end.
  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.

Fig 5: Removing Rack End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.

SST 09922-10010

NOTE: Use SST 09922-10010 in the direction shown in the illustration.

Fig 6: Removing Rack Guide Spring Cap Lock Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RACK GUIDE SPRING CAP
REMOVE RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
REMOVE DUST COVER
REMOVE CONTROL VALVE HOSING WITH CONTROL VALVE ASSEMBLY
1. Place matchmarks on the valve housing and rack housing.
2. Remove the 2 bolts.
3. Pull out the control valve assembly with the valve housing.
4. Remove the O-ring from the valve housing.
Fig 7: Placing Matchmarks On Valve Housing & Rack Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL VALVE ASSEMBLY
1. Using SST, loosen the bearing guide nut.
  SST 09631-20060
  
  Fig 8: Loosening Bearing Guide Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Wind vinyl tape to the control valve shaft.
3. Using a plastic hammer, tap out the valve assembly with the nut from the control valve housing.
  
  Fig 9: Removing Taped Valve Assembly From Control Valve Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the oil seal lip.
4. Remove the nut from the valve assembly.
  NOTE: Be careful not the damage the oil seal lip.
5. Remove the O-ring from the nut.
REMOVE CYLINDER END STOPPER AND SPACER
1. Using SST, remove the stopper.
  SST 09922-10010
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
2. Remove the O-ring from the stopper.
Fig 10: Removing Cylinder End Stopper
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STEERING RACK AND OIL SEAL
1. Using SST, press out the rack and oil seal.
  NOTE: Take care not to drop the rack.
  
  SST 09950-70010 (09951-07200)
2. Remove the oil seal from the rack.
Fig 11: Removing Steering Rack & Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL SEAL AND SPACER
Using SST, press out the oil seal and spacer.

SST 09950-60010 (09951-00360), 09950-70010 (09951-07360)

Fig 12: Removing Oil Seal & Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002