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Power Steering Gear: Disassembly

NOTE: When using a vise, do not overtighten it.
  1. Remove 2 turn pressure tubes  :
    1. Using SST, remove the 2 turn pressure tubes.
      1. SST 09023-38200
      Fig 1: Removing Turn Pressure Tubes
      G01026057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 union seats from the rack housing and control valve housing.
    2. NOTE: Use 2 of the same type of SST.
  2. Using SST and 2 bolts, secure the gear assembly in a vise, as shown. 
    1. SST 09612-00012
      Fig 2: Securing Power Steering Gear In Vise
      G01026058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Reference: 

    1. Bolt: 90105-10346 
    2. Nut: 90170-10198 

  3. 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
      G01026059Courtesy 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.
  4. Remove RH and LH clips, rack boots and clamps  :
    1. Remove the clamp, clip and rack boot.
      CAUTION: Be careful not to damage the boot.
      NOTE: Mark the RH and LH boots.
    2. Employ the same manner described above to the other side.
  5. 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 4: Unstaking Washer
      G01026060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. NOTE: Mark the RH and LH rack ends.

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

      Fig 5: Removing Steering Rack End
      G01026061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a spanner to hold the steering rack steadily, and using SST, remove the rack end.
      1. SST 09922-10010
    3. Remove the claw washer from the rack end.
    4. Employ the same manner described above to the other side.
    6. NOTE: Use SST 09922-10010 in the direction shown in the illustration.
    Fig 6: Removing Rack Guide Spring Cap
    G01026062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Using SST, remove rack guide spring cap lock nut  .
    1. SST 09922-10010
  7. Remove rack guide spring cap  .
  8. Remove rack guide spring and rack guide  .
  9. Remove dust cover  .
  10. Remove control valve housing with control valve assembly  :
    1. Place matchmarks on the control valve housing and rack housing.
      Fig 7: Placing Matchmarks On Control Valve & Rack Housing
      G01026063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts.
    3. Pull out the control valve assembly with the control valve housing.
    4. Remove the "O" ring from the rack housing.
  11. Remove control valve assembly  :
    1. Using SST, loosen the bearing guide nut.
      1. SST 09631-20060
      Fig 8: Removing & Installing Bearing Guide Nut
      G01026064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Wind vinyl tape to the control valve shaft.
      3. NOTE: Be careful not to damage the oil seal lip.
      Fig 9: Removing Control Valve Assembly
      G01026065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a plastic hammer, tap out the control valve assembly with the bearing guide nut from the control valve housing.
      4. 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.
  12. Remove cylinder end stopper  :
      NOTE: Use SST 09922-10010 in the direction shown.
      Fig 10: Removing Cylinder End Stopper
      G01026066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the cylinder end stopper.
      1. SST 09922-10010
    2. Remove the "O" ring from the cylinder end stopper.
  13. Remove steering rack and oil seal  :
      CAUTION: Take care not to drop the rack.
      Fig 11: Removing Steering Rack & Oil Seal
      G01026067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, press out the steering rack and oil seal.
      1. SST 09950-70010 (09951-07360)
    2. Remove the oil seal from the steering rack.
  14. Using SST, press out the oil seal and spacer. 
    1. SST 09950-60010 (09951-00360), 09950-70010 (09951-07360)
      Fig 12: Removing Rack Housing Oil Seal & Spacer
      G01026068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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