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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: Securing Gear Assembly In Vise Using SST
    G02818299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09612-00012

  2. REMOVE 2 TURN PRESSURE TUBES 
    1. Using SST, remove the 2 turn pressure tubes.
      Fig 2: Removing Turn Pressure Tubes Using SST
      G02818300Courtesy 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.
      2. Fig 3: Placing Matchmarks On Tie Rod End, Lock Nut & Rack End
      G02818301Courtesy 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 
    Fig 4: Removing RH And LH Clips, Rack Boots & Clamps
    G02818302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, loosen the clamp.
      NOTE: Be careful not to damage the rack boot.
    2. Remove the clip and rack boot.
    3. Employ the same manner described above to the other side.
    NOTE: Mark the RH and LH rack boot.
  5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS 
    1. Using a screwdriver and hammer, unstake the claw washer.
      Fig 5: Unstaking Claw Washer Using A Screwdriver & Hammer
      G02818303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Avoid any impact on the steering rack.
    2. Using a spanner (24 mm) hold the steering rack steadily and using SST, remove the rack end.
      Fig 6: Removing Rack End Using A Spanner
      G02818304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09922-10010

      NOTE: Use SST 09922-10010 in the direction shown. See Fig 6.
    3. Remove the claw washer.
    4. Employ the same manner described above to the other side.
    NOTE: Mark the RH and LH rack ends.
  6. REMOVE RACK GUIDE SPRING CAP LOCK NUT 

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

    Fig 7: Removing Rack Guide Spring Cap Lock Nut Using SST
    G02818305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09922-10010

    NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE SUB-ASSEMBLY 
    1. Using SST, remove the rack guide spring cap.
      Fig 8: Removing Rack Guide Spring Cap Using SST
      G02818306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09631-10021

    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 9: Removing Self-Locking Nut Using SST
    G02818307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    SST 09616-00011

  10. REMOVE DUST SEAL 
  11. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY 
    1. Place matchmarks on the control valve housing and rack housing.
      2. Fig 10: Placing Matchmarks On Control Valve Housing & Rack Housing
      G02818308Courtesy 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 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 11: Removing Control Valve Assembly
    G02818309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Placing Matchmarks On Rack Housing No. 2 Bracket & Rack Housing
      G02818310Courtesy 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.
      3. Fig 13: Prying Clamp Of Rack Housing No. 2 Bracket Using A Screwdriver
      G02818311Courtesy 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.
      Fig 14: Removing Cylinder End Stopper Using SST
      G02818312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09631-10021

  16. REMOVE STEERING RACK AND BUSHING 
    Fig 15: Removing Steering Rack & Bushing
    G02818313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a brass bar and hammer, tap out the steering rack with the bushing.
    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 16: Removing Oil Seal Using SST
    G02818314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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