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Power Steering Gear: Disassembly

NOTE: When using a vise, do not overtighten it.
  1. Secure PS gear assembly in vise  :

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

    Fig 1: Identifying SST 09612-00012
    G01050854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09612-00012

  2. Remove 2 turn pressure tubes  :
    1. Using SST, remove the tube.
      Fig 2: Identifying SST 09023-38200
      G01050855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09023-38200

    2. Remove the 4 "O" rings from the 2 turn pressure tubes.
  3. Remove RH and LH tie rod ends and lock nuts  :
    1. Place matchmarks on the tie rod end and rack end.
      Fig 3: Matchmarking Tie Rod & Rack End
      G01050856Courtesy 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.
  4. Remove RH and LH clips, rack boots and clamps  :
      CAUTION: Be careful not to damage the boot.
      Fig 4: Removing Boot Clamp
      G01050857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, loosen the clamp.
    2. Remove the clip and rack boot.
      3. NOTE: Mark the RH and LH rack boot.
    3. Employ the same manner described above to the other side.
  5. Remove RH and LH rack ends and claw washers  :
      CAUTION: Avoid any impact on the steering rack.
      Fig 5: Unstaking Claw Washer
      G01050858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver and a hammer, unstake the claw washer.
    2. Using a spanner (24 mm) to hold the steering rack steadily and using SST, remove the rack end.
      Fig 6: Removing Rack End
      G01050859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09922-10010

      NOTE: Use SST 09922-10010 in the direction shown in Fig 6.
    3. Remove the claw washer from the rack end.
      4. NOTE: Mark the RH and LH rack ends.
    4. Employ the same manner described above to the other side.
    6. NOTE: Use SST 09922-10010 in the direction shown in Fig 7.
    Fig 7: Removing Rack Guide Spring Cap Lock Nut
    G01050860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove rack guide spring cap lock nut  :

    Using SST, remove the rack guide spring cap lock nut.

    SST 09922-10010

  7. Remove rack guide spring cap, rack guide spring, rack guide sub-assembly  :
    1. Using a hexagon wrench (21 mm), remove the rack guide spring cap.
    2. Remove the rack guide spring and rack guide sub-assembly.
  8. Remove rack housing cap  .
  9. Remove self-locking nut  .

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

    Fig 8: Identifying Self-Locking Nut
    G01050861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09616-00011

  10. Remove dust cover  .
  11. Remove control valve housing with control valve assembly  :
    1. Place matchmarks on the control valve housing and rack housing.
      Fig 9: Matchmarking & Removing Control Valve Housing & Assembly
      G01050862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and control valve housing.
    3. Remove the gasket from the rack housing.
  12. Remove control valve assembly  :
    1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
    2. Press out the control valve assembly with the oil seal.
      NOTE:
      • Place a shop rag between the valve housing and the blocks.
      • Be careful not to drop the control valve assembly.
      • Be careful not to damage the oil seal lip.
  13. Remove oil seal  :

    Remove the oil seal from the control valve assembly.

    Fig 10: Pressing Out Control Valve Assembly
    G01050863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Remove rack housing No. 2 bracket and grommet  :
    1. Place matchmarks on the rack housing No. 2 bracket and rack housing.
      Fig 11: Matchmarking Rack Housing No. 2 Bracket & Grommet
      G01050864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, pry the clamp of the rack housing No. 2 bracket.
      Fig 12: Prying Off Rack Housing No. 2 Bracket
      G01050865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the rack housing No. 2 grommet from the rack housing No. 2 bracket.
  15. Remove cylinder end stopper  :
    1. Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
      Fig 13: Removing Cylinder End Stopper
      G01050866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09631-10021

    2. Using SST, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.

      SST 09631-10021

  16. Remove steering rack and bushing  :
    1. Using a brass bar and a hammer, tap out the rack with the bushing.
      Fig 14: Punching Out Steering Rack Bushing
      G01050867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bushing from the steering rack.
    3. Remove the "O" ring from the bushing.
  17. Remove oil seal  :

    Using SST, press out the oil seal.

    Fig 15: Pressing Out Steering Rack Oil Seal
    G01050868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09950-60010 (09951-00290), 09950-70010 (09951-07360)

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