Power Steering Gear: Disassembly

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

REMOVE TURN PRESSURE TUBES
1. Using SST, remove the 2 turn pressure tubes.
  SST 09023-38200
2. Remove the 4 O-rings from the 2 turn pressure tubes.
Fig 1: Removing O-Rings From Turn Pressure Tubes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the PS gear assembly in a vise.

SST 09612-00012

Fig 2: Securing PS Gear Assembly In Vise Using SST
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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.
  HINT:
  
  Mark the RH and LH tie rod ends and lock nuts.
3. Employ the same manner described above to the other side.
Fig 3: Placing Matchmarks On Tie Rod And Rack End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH CLIPS, CLAMPS AND RACK BOOTS
1. Using a screwdriver, loosen the clamp.
2. Remove the clip, clamp and rack boot.
  NOTE: Be careful not to damage the boot.
  
  HINT:
  
  Mark the RH and LH rack boots.
3. Employ the same manner described above to the other side.
Fig 4: Loosening Clamp Using Screwdriver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH RACK ENDS
1. Using SST, hold the LH rack end steadily and using another SST, remove the RH rack end.
  SST 09922-10010
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  
  HINT:
  
  Mark the RH and LH rack ends.
  
  Fig 5: Identifying SST Locations
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, hold the steering rack RH side steadily and using another SST, remove the LH rack end.
  SST 09922-10010
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  
  HINT:
  
  Mark the RH and LH rack ends.
  
  Fig 6: Identifying SST Locations
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the rack guide spring cap lock nut.

SST 09922-10010

Fig 7: Removing Rack Guide Spring Cap Lock Nut Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Use SST 09922-10010 in the direction shown in the illustration.
REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING AND RACK GUIDE SUBASSEMBLY
1. Using a hexagon wrench (19 mm), remove the rack guide spring cap.
2. Remove the rack guide spring and rack guide subassembly.
REMOVE RACK HOUSING CAP
REMOVE SELF-LOCKING NUT
Using SST, stop the control vale shaft rotating and remove the self-locking nut.

SST 09616-00011

Fig 8: Removing Self-Locking Nut Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
1. Remove the dust seal.
2. Place matchmarks on the control valve housing and rack housing.
3. Remove the 2 bolts.
4. Pull out the control valve housing with control valve assembly.
5. Remove the gasket.
Fig 9: Placing Matchmarks On Control Valve Housing And Rack Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL VALVE ASSEMBLY
1. Wind vinyl tape on the control valve shaft.
2. Press out the control valve assembly.
Fig 10: Winding Vinyl Tape On Control Valve Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE OIL SEAL OF CONTROL VALVE ASSEMBLY
Remove the oil seal from the control valve assembly.
REMOVE CYLINDER END STOPPER
1. Using needle nose pliers, remove the snap ring.
2. Pull out the cylinder end stopper.
REMOVE STEERING RACK WITH BUSHING
1. Using SST, press out the steering rack with the bushing.
  SST 09950-70010 (09951-07200)
  
  NOTE: Take care not to drop the steering rack.
2. Remove the O-ring from the bushing.
Fig 11: Removing Steering Rack With Bushing Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002