Power Steering Gear: Disassembly

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

FIX POWER STEERING GEAR ASSEMBLY
1. Using SST, fix the gear assembly in a vise, as shown in the illustration.
  SST 09630-00014 (09631-00142)
  
  Fig 1: Fixing Gear Assembly In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TURN PRESSURE TUBE ASSEMBLY
1. Using SST, remove the 2 tubes.
  SST 09023-38201
  
  Fig 2: Removing Tubes Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLIP, RACK BOOT AND CLAMP
1. Using pliers, loosen the clamp, as shown in the illustration.
  NOTE: Be careful not to damage the boot.
2. Remove the clip, rack boot and clamp.
3. Use the same procedure described above for the other side.
  
  Fig 3: Removing Clip Using Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Mark the RH and LH rack boots.
REMOVE STEERING RACK END
1. Using a screwdriver and hammer, shake back the washer.
  NOTE: Avoid any impact to the steering rack.
  
  Fig 4: Shaking Back Washer Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a spanner to hold the steering rack steady, and using SST, remove the rack end.
  SST 09922-10010
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
3. Remove the claw washer.
4. Use the same procedure described above for the other side.
  HINT:
  
  Mark the RH and LH rack boots.
  
  Fig 5: Holding Steering Rack Steady, Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RACK GUIDE SPRING CAP LOCK NUT
1. Using SST, remove the lock nut.
  SST 09922-10010
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  
  Fig 6: Removing Lock Nut Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RACK GUIDE SPRING CAP
REMOVE RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
REMOVE DUST COVER
REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
1. Place matchmarks on the valve housing and rack housing.
2. Remove the 2 bolts.
3. Pull out the control valve assembly with the valve housing.
4. Remove the O-ring from the valve housing.
  
  Fig 7: Identifying Matchmarks On Valve Housing And Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL VALVE ASSEMBLY
1. Using SST, loosen the bearing guide nut.
  SST 09631-20060
  
  Fig 8: Removing Bearing Guide Nut Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Wind vinyl tape to the control valve shaft.
3. Using a plastic hammer, tap out the valve assembly with the nut from the control valve housing.
  NOTE: Be careful not to damage the oil seal lip.
4. Remove the nut from the valve assembly.
  NOTE: Be careful not to damage the oil seal lip.
5. Remove the O-ring from the nut.
  
  Fig 9: Tapping To Control Valve Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CYLINDER END STOPPER AND SPACER
1. Using SST, remove the stopper.
  SST 09922-10010
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
2. Remove the O-ring from the stopper.
  
  Fig 10: Removing Stopper Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STEERING RACK AND OIL SEAL
1. Using SST, press out the rack and oil seal.
  NOTE: Take care not to drop the rack.
  
  SST 09950-70010 (09951-07200)
2. Remove the oil seal from the rack.
  
  Fig 11: Removing Oil Seal From Rack Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002