Power Steering Gear: Disassembly

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

REMOVE TURN PRESSURE TUBES
Using SST, remove the 2 turn pressure tubes.

SST 09023-38201

Fig 1: Removing 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: Placing PS Gear Assembly In Vise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
3. Employ the same manner described above to the other side.
  HINT:
  
  Mark the RH and LH tie rod ends and lock nuts.
  
  Fig 3: Placing Matchmarks On Tie Rod End & Rack End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH CLIPS, CLAMPS AND RACK BOOTS
1. Loosen the clamp screw.
2. Remove the clip, clamp and rack boot.
  NOTE: Be careful not to damage the boot.
3. Employ the same manner described above to the other side.
  HINT:
  
  Mark the RH and LH rack boots.
REMOVE RH AND LH RACK ENDS AND CLAW WASHERS
1. Using a screwdriver and a hammer, unstake the claw washer.
  NOTE: Avoid any impact on the steering rack.
  
  Fig 4: Removing RH & LH Rack Ends & Claw Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and spanner (22 mm), remove the power steering rack and claw washer. See Fig 5.
  SST 09922-10010
  
  HINT:
  
  Using spanner, hold the steering rack to remove the rack end and claw washer.
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  
  HINT:
  
  Mark the RH and LH rack ends.
3. Using 2 SST, remove the other rack end.
  HINT:
  
  Using SST, hold the power steering rack to remove the rack end and claw washer.
REMOVE RACK GUIDE
1. Using a straight hexagon wrench 24, remove the rack guide spring cap.
2. Remove the rack guide spring and rack guide.
  
  Fig 5: Removing Rack Guide Spring Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
1. Place matchmarks on the control valve housing and rack housing.
2. Remove the 2 bolts.
3. Pull out the control valve housing with control assembly.
4. Remove the gasket
  SST 09616-00011
  
  Fig 6: Placing Matchmarks On Control Valve Housing & Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL VALVE ASSEMBLY, UPPER OIL SEAL AND UPPER BEARING
1. Wind vinyl tape on the control valve shaft.
2. Press out the control valve assembly.
  SST 09613-12010
  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.
3. Remove the oil seal and bearing from the control valve assembly.
  
  Fig 7: Pressing Out Control Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER END STOPPER
1. Place rack housing in vise.
  NOTE: Hold the arrow part in the illustration in a vice. See Fig 8.
2. Using SST, remove the cylinder end stopper from the rack housing.
  SST 09631-20120
3. Using a screwdriver, remove the O-ring from the cylinder end stopper.
  NOTE: Do not damage the cylinder end stopper.
4. Using a screwdriver, remove the rack guide bush from the cylinder end stopper.
  NOTE: Do not damage the cylinder end stopper.
  
  Fig 8: Removing Cylinder End Stopper From Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE POWER STEERING RACK

Using a service bolt and press, remove the steering rack from the steering rack housing. See Fig 9.

Recommended service bolt:

SERVICE BOLT SPECIFICATION

Thread diameter	14 mm (0.55 in.)
Thread pitch	1.5 mm (0.059 in.)

Fig 9: Removing Steering Rack From Steering Rack Housing

Using a screwdriver, remove the power piston oil seal and power piston O-ring from the steering rack.
NOTE: Do not damage the steering rack ring groove.
Remove the cylinder end stopper oil seal from the steering rack.

REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
1. Using needle nose pliers, remove the bush from the rack housing.
  
  Fig 10: Removing Bushing From Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install SST (09612-07130) on SST (09612-07210). See Fig 11.
3. Diagonally insert SST (09612-07210) into the housing until it contacts with the oil seal, and then, further insert the SST (09612-07210) until the tip of SST (09612-07220) contacts with SST (09612-07130).
  SST 09612-70100 (09612-07130, 09612-07210, 09612-07220)
  
  NOTE: Do not damage the inside of the housing.
  
  Fig 11: Inserting SST Into Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Secure SST (09612-07220), and pull SST (09612-07210) to place SST (09612-07130) in the housing.
  SST 09612-70100 (09612-07130, 09612-07210, 09612-07220)
  
  HINT:
  
  Place SST on the chamfering position between the oil seal and rack housing.
5. Remove the SST (09612-07210, 09612-07220).
  SST 09612-07100 (09612-07210, 09612-07230
  
  Fig 12: Removing SST From Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. After installing SST (09612-07240) on SST (09612-07210), insert the tip of SST (09612-07230) in the service hole of SST (09612-07130).
  SST 09612-70100 (09612-07130, 09612-07230, 09612-07240)
  
  Fig 13: Inserting Tip Of SST In Service Hole Of SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Before using them, apply a small dab of grease to the tip of SST (09612-07130).
  - To prevent SST (09612-07130) from being damaged, be sure to install SST (09612-07240).
  - Do not damage the inside of the rack housing.
7. Install SST (09951-07100) on SST (09612-07230) and remove the oil seal using a press.
  SST 09612-70100 (09612-07130, 09612-07230, 09612-07240), 09950-70010 (09951-07100)
  
  NOTE: Do not damage the rack housing.
  
  HINT:
  
  Replace SST (09951-07100) with SST that is different in length in the set, if necessary.
  
  Fig 14: Removing Oil Seal From Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002