Power Steering Gear: Disassembly

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

SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise, as shown in Fig 1 .
1. SST 09630-00014 (09631-00142)
Fig 1: Securing PS Gear Assembly In Vise
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 TURN PRESSURE TUBES
Using SST, remove the tube.
1. SST 09023-38200
Fig 2: Removing 2 Turn Pressure Tubes
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
1. Using pliers, loosen the clamp, as shown in Fig 3 .
  NOTE: Be careful not to damage the boot.
2. Remove the clip, rack boot and clamp.
3. Employ the same manner described above to the other side.
Fig 3: Locating & Loosening Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Mark the RH and LH rack boots.
REMOVE RH AND LH RACK ENDS AND CLAW WASHERS
1. Using a screwdriver and hammer, stake back the washer.
  
  Fig 4: Stacking Back Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Avoid and impact to the steering rack.
2. Using a spanner to hold the steering rack steady, and using SST, remove the rack end.
  1. SST 09922-10010
  NOTE: Use SST 09922-10010 in the direction shown in Fig 5 .
3. Remove the claw washer.
4. Employ the same manner described above to the other side.
Fig 5: Removing Rack End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Mark the RH and LH rack ends.
REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
1. SST 09922-10010
NOTE: Use SST 09922-10010 in the direction shown in Fig 6 .
REMOVE RACK GUIDE SPRING CAP
REMOVE RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
REMOVE CONTROL VALVE HOSING 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: Placing Matchmarks On Valve Housing & Rack Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CONTROL VALVE ASSEMBLY
1. Using SST, loosen the bearing guide nut.
  1. SST 09631-20060
  Fig 8: Loosening Bearing Guide Nut
  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.
  
  Fig 9: Tapping Out Valve Assembly With Nut From Control Valve Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the oil seal lip.
4. Remove the nut from the valve assembly.
  NOTE: Be careful not the damage the oil seal lip.
5. Remove the O-ring from the nut.
REMOVE CYLINDER END STOPPER AND SPACER
1. Using SST, remove the stopper.
  1. SST 09922-10010
  Fig 10: Removing Cylinder End Stopper & Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Use SST 09922-10010 in the direction shown in Fig 11 .
2. Remove the O-ring from the stopper.
REMOVE STEERING RACK AND OIL SEAL
1. Using SST, press out the rack and oil seal.
  
  Fig 11: Pressing Out Rack & Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Take care not to drop the rack.
  1. SST 09950-70010 (09951-07200)
2. Remove the oil seal from the rack.