LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2002 >> Avalon XLS >> Repair and Diagnosis >> Steering >> Power Steering >> Steering System >> Power Steering Gear >> Disassembly

Power Steering Gear: Disassembly

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

    Using SST, Secure PS Gear Assembly In A Vise. SST 09612-00012.

    Fig 1: Identifying SST & Securing PS Gear Assembly
    G01102408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove 2 turn pressure tubes:
    1. Using SST, remove the 2 turn pressure tubes. SST 09023-38200.
      Fig 2: Locating Turn Pressure Tubes
      G01102409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Placing Match Marks On Tie Rod End
      G01102410Courtesy 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:
    NOTE: Mark the RH and LH rack boot.
      CAUTION: Be careful not to damage the rack boot.
      Fig 4: Removing Rack Boot Clamps
      G01102411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, loosen the clamp.
    2. Remove the clip and rack boot.
    3. Employ the same manner described above to the other side.
  5. Remove RH and LH rack ends and claw washers:
      NOTE: Avoid any impact on the steering rack.
      Fig 5: Unstaking Claw Washer
      G01102412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver and hammer, unstake the claw washer.
      2. NOTE: Use SST 09922-10010 in the direction shown in Fig 6.

      Mark the RH and LH rack ends.

      Fig 6: Removing Rack End
      G01102413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a spanner (24 mm) hold the steering rack steadily and using SST, remove the rack end. SST 09922-10010.
    3. Remove the claw washer.
    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
    G01102414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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 SST, remove the rack guide spring cap. SST 09631-10021.
    2. Remove the rack guide spring and rack guide sub-assembly.
  8. Remove rack housing cap.
    Fig 8: Removing Rack Housing Cap
    G01102415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Using SST, stop the control valve shaft rotating and remove the self-locking nut. SST 09616-00011.
    Fig 9: Removing Self-Locking Nut
    G01102416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Remove dust seal.
  11. Remove control valve housing with control valve assembly:
    1. Place matchmarks on the control valve housing and rack housing.
      Fig 10: Matchmarking & Removing Control Valve Housing & Assembly
      G01102417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and control valve housing.
    3. Remove the gasket from the rack housing.
    12. 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.
  12. Remove control valve assembly:
    1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
      Fig 11: Pressing Out Control Valve Assembly
      G01102418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Press out the control valve assembly with the oil seal.
  13. Remove the oil seal from the control valve assembly.
  14. Remove rack housing No. 2 bracket and rack housing No. 2 grommet:
    1. Place matchmarks on the rack housing No. 2 bracket and rack housing.
      Fig 12: Matchmarking Rack Housing & No. 2 Bracket
      G01102419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, pry the clamp of the rack housing No. 2 bracket and remove the rack housing No. 2 bracket.
      Fig 13: Removing Rack Housing No. 2 Bracket Clamp
      G01102420Courtesy 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. SST 09631-10021.
    2. Using SST, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper. SST 09631-10021.
      Fig 14: Removing Cylinder End Stopper
      G01102421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Remove steering rack and bushing:
    1. Using a brass bar and hammer, tap out the steering rack with the bushing.
      Fig 15: Punching Out Steering Rack Bushing
      G01102422Courtesy 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. SST 09950-60010 (09951-00290), 09950-70010 (09951-07360)

    Fig 16: Punching Out Steering Rack Oil Seal
    G01102423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals