Power Steering Gear: Disassembly

WARNING: This page is about a different car, the 2002 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

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

Remove 2 turn pressure tubes .
1. Using SST, remove the 2 turn pressure tubes. SST 09023-12700.
  
  Fig 1: Removing Turn Pressure Tubes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 "O" rings from the tubes.
Secure PS gear assembly in vise .
Using SST, 2 bolts and nuts, secure the gear assembly in a vise, as shown in Fig 2. SST 09612-00012.

Reference: Bolt: 90105-10346, Nut: 90170-10198.

NOTE: Use 2 of the same type of SST.

Fig 2: Securing Power Steering Gear In Vise
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.
  
  Fig 3: Matchmarking Tie Rod Ends & Lock Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the lock nut, remove the tie rod end and lock nut.
3. Employ the same manner described above to the other side.
Remove RH and LH clips, rack boots and clamps .
1. Using a screwdriver, loosen the 2 clamps.
  
  Fig 4: Removing Boot Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 clips and boots.
  NOTE: Mark the RH and LH boots.
  Be careful not to damage the boot.
Remove RH and LH rack ends and claw washers .
1. Using a screwdriver and hammer, unstake the washer.
  CAUTION: Avoid any impact on the steering rack.
  
  Fig 5: Unstaking Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a spanner to hold the steering rack steadily, and using SST, remove the rack end. SST 09922-10010.
  NOTE: Mark the RH and LH rack ends.
  Use SST 09922-10010 in the direction shown in Fig 6.
  
  Fig 6: Removing Steering Rack Ends
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the washer from the rack end.
4. Employ the same manner described above to the other side.
Remove rack guide spring cap lock nut .
Using SST, remove the lock nut. SST 09922-10010.

NOTE: Use SST 09922-10010 in the direction shown in Fig 7.

Fig 7: Removing Rack Guide Spring Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove rack guide spring cap, rack guide spring and rack guide .
1. Using a hexagon wrench, remove the rack guide spring cap.
2. Remove the rack guide spring and rack guide.
Remove rack housing cap .
Using SST, remove the rack housing cap. SST 09816-30010.

Fig 8: Removing Rack Housing Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove self-locking nut .
Using SST to stop the control valve shaft rotating, remove the nut. SST 09616-00011.

Fig 9: Removing Self-Socking Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove dust cover .
Remove control valve housing with control valve assembly .
1. Place matchmarks on the control valve housing and rack housing.
  
  Fig 10: Placing Matchmarks & Locating Control Valve Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and control valve housing with control valve assembly.
3. Remove the gasket from the rack housing.
Remove control valve assembly .
1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
2. Press out the valve assembly with the oil seal.
  
  Fig 11: Remove Control Valve Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Place a shop rag between the valve housing and the blocks.
  - Be careful not to drop the valve assembly.
  - Be careful not to damage the oil seal lip.
Remove oil seal .
Remove the oil seal from the control valve assembly.
Remove cylinder end stopper .
1. Using SST, turn the stopper clockwise until the wire end is visible through the service hole. SST 09631-16010.
  
  Fig 12: Removing Cylinder End Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, turn the stopper counterclockwise, and remove the wire. SST 09631-16010.
Remove steering rack and bushing .
1. Using SST, press out the steering rack with the bushing. SST 09950-70010 (09951 -07200).
  CAUTION: Take care not to drop the rack.
  
  Fig 13: Removing Steering Rack & Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bushing from the rack.
3. Remove the "O" ring from the bushing.
Remove oil seal .
Using SST, press out the oil seal. SST 09950-60010 (09951-00360),09950-70010 (09951-07360).

Fig 14: Removing Rack Housing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002