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Steering Gear: Disassembly

CAUTION: When using a vise, do not overtighten it.
NOTE: Use Figure-Figure for reference.
  1. Using the Rack & Pinion Steering Rack Housing Stand (SST 09612-00012), secure the gear assembly in a vise. See Fig 1.
    Fig 1: Securing Gear Assembly
    G00131907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove 2 turn pressure tubes. Using the Power Steering Hose Nut Wrench (SST 09633-00020), remove the tube. See Fig 2. Remove the 2 O-rings from the tube.
    Fig 2: Removing Two Turn Pressure Tubes
    G00131908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove the right hand and left hand tie rod ends and lock nuts. Place matchmarks on the tie rod end and rack end. See Fig 3. Loosen the lock nut.
    Fig 3: Removing Tie Rod Ends & Lock Nuts
    G00131909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. CAUTION: Be careful not to damage the boot. Mark the right hand and left hand boots.
    Fig 4: Removing Clamps
    G00131910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove right hand and left hand clips, rack boots and clamps. Using a screwdriver, loosen the clamp. See Fig 4.
    5. CAUTION: Avoid any impact to the steering rack. Mark the right hand and left hand rack ends.
    NOTE: Use the Variable Open Wrench in the direction shown in illustration. See Fig 5.
    Fig 5: Removing Rack Ends
    G00131912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Removing Claw Washers
    G00131911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove right hand and left hand rack ends and claw washers. Using a screwdriver and hammer, unstake the washer. See Fig 6. Using a 24 mm spanner to hold the steering rack steady, and using the Variable Open Wrench (SST 09922-10010), remove the rack end.
    6. NOTE: Use the Variable Open Wrench in the direction shown in illustration. See Fig 7.
    Fig 7: Removing Rack Guide Spring Cap Lock Nut
    G00131913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove the rack guide spring cap lock nut. Using the Variable Open Wrench (SST 09922-10010), remove the nut.
  7. Remove the rack guide spring cap, rack guide spring, rack guide and rack guide seat. Using the Rack Stopper Wrench (SST 09631-10021), remove the cap. See Fig 8. Remove the seat from the guide.
    Fig 8: Removing Rack Guide Spring Cap
    G00131914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Remove the rack housing cap.
  9. Remove the self-locking nut. Using the Steering Worm Bearing Adjusting Socket (SST 09616-00010) to stop the control valve shaft rotating, remove the nut. See Fig 9.
    Fig 9: Removing Self-Locking Nut
    G00131915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Remove the dust cover.
  11. Remove the control valve housing with control valve assembly. Place matchmarks on the valve housing and rack housing. See Fig 10. Remove the 2 bolts. Remove the gasket from the rack housing.
    Fig 10: Removing Control Valve Housing
    G00131916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. CAUTION: Place a shop rag between the valve housing and the blocks. Be careful not to drop the valve assembly and not to damage the oil seal lip.
    Fig 11: Removing Control Valve Assembly
    G00131917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Remove control valve assembly. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. See Fig 11. Press out the valve assembly with the oil seal.
  13. Remove the oil seal from the control valve assembly.
  14. Remove the rack housing No. 2 bracket and grommet. Place matchmarks on the bracket and rack housing. See Fig 12. Using a screwdriver, pry apart the clamp off the bracket. See Fig 13. Remove the grommet from the bracket.
    Fig 12: Removing Rack Housing No. 2 Bracket
    G00131918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 13: Removing Rack Housing No. 2 Bracket Clamp
    G00131919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Remove cylinder end stopper. Using the Rack Stopper Wrench (SST 09631-10021), turn the stopper clockwise until the wire end is visible through the service hole. See Fig 14. Using the Rack Stopper Wrench (SST 09631-10021), turn the stopper counterclockwise, and remove the wire.
    Fig 14: Removing Cylinder End Stopper
    G00131920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Remove the steering rack and bushing. Using a brass bar and hammer, tap out the rack with the bushing. See Fig 15. Remove the O-ring from the bushing.
    Fig 15: Removing Steering Rack & Bushing
    G00131921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. CAUTION: Do not damage the rack housing.
  17. Remove the oil seal. Using the Replacer Set: Replacer 29 and Handle Set: Handle 360 (SST 09950-60010, 09951-00290, 09950-70010, 09951-07360), press out the oil seal. See Fig 16.
Fig 16: Removing Oil Seal
G00133002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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