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 09023-38200

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.
1. SST 09612-00012
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.
NOTE: Mark the RH and LH tie rod ends and lock nuts.
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.
NOTE: 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.
  
  Fig 4: Unstaking Claw Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Avoid any impact on the steering rack.
2. Using a spanner (22 mm), hold the steering rack steadily and using SST, remove the rack end.
  1. SST 09922-10010
  NOTE: Use SST 09922-10010 in the direction shown.
3. Remove the claw washer.
4. Employ the same manner described above to the other side.
NOTE: Mark the RH and LH rack ends.
Remove No. 1 rack housing bracket and grommet .
1. Place matchmarks on the No. 1 rack housing bracket and rack housing.
2. Remove the bolt and bracket.
3. Remove the grommet from the bracket.
  
  Fig 6: Placing Matchmarks On No. 1 Housing Bracket & Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove rack guide spring cap lock nut .
Using SST, remove the rack guide spring cap lock nut.
1. SST 09922-10010
NOTE: Use SST 09922-10010 in the direction shown.
Remove rack guide spring cap, rack guide spring, conical spring and rack guide .
1. Using a hexagon wrench (21 mm), remove the rack guide spring cap.
2. Remove the rack guide spring, conical spring and rack guide.
Remove rack housing cap .
Remove self-locking nut .
Using SST, stop the control valve shaft rotating and remove the self-locking nut.
1. SST 09616-00011
Remove control valve assembly, upper oil seal and upper bearing .
1. Using snap ring pliers, remove the snap ring from the rack housing.
  
  Fig 9: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the control valve assembly with the oil seal and upper bearing.
  1. SST 09613-12010
  NOTE: Never attempt to tap out the control valve as this would damage it.
3. Remove the oil seal and bearing from the control valve assembly.
Remove cylinder end stopper .
1. Using snap ring pliers, remove the snap ring from the rack housing.
2. Remove the cylinder end stopper.
Remove steering rack and oil seal .
1. Using a brass bar, press out the steering rack with the oil seal.
2. Remove the oil seal from the steering rack.
  
  Fig 10: Locating Steering Rack & Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002