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Power Steering Gear: Removal

NOTE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable.
  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  2. REMOVE STEERING WHEEL PAD (See  REMOVAL  ) 
  3. REMOVE STEERING WHEEL (See  REMOVAL  ) 
  4. REMOVE RH AND LH ENGINE UNDER COVERS 
  5. DISCONNECT RH AND LH TIE ROD ENDS (See  REMOVAL  ) 
  6. REMOVE NO. 2 COLUMN HOLE COVER (See  REMOVAL  ) 
  7. DISCONNECT SLIDING YOKE (See  REMOVAL  ) 
  8. DISCONNECT PRESSURE FEED AND RETURN TUBES 
    1. Disconnect the column hole cover sub-assembly.
    2. Remove the clip and disconnect the return hose.
    3. Using SST, disconnect the pressure feed and return tubes.

      SST 09023-12900

    Fig 1: Disconnecting Pressure Feed And Return Tubes Using SST
    G02575729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT TUBE CLAMP 

    Remove the bolt and disconnect the tube clamp.

  10. REMOVE ENGINE HOOD (See  HOOD  ) 
    Fig 2: Removing Bolt And Tube Clamp
    G02575730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS 
    1. Install the 2 No. 1 engine hangers with the bolt in the correct direction.

      Parts No.: 

      No. 1 engine hangerndash;21010 

      Bolt: 91511-60818 

      Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

      Fig 3: Installing Engine Hangers
      G02575731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the engine chain hoist to the engine hangers.
    CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
  12. DISCONNECT LOWER SUSPENSION ARM FROM STEERING KNUCKLE (See  REMOVAL  ) 
  13. DISCONNECT ENGINE REAR MOUNT INSULATOR AND FRONT SUSPENSION MEMBER 

    Remove the bolt and 2 nuts, and disconnect the engine rear mount insulator and front suspension member.

  14. SUPPORT FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM 

    Using a transmission jack, support the front suspension member with lower suspension arm.

    Fig 4: Removing Bolts And Front Suspension Member
    G02575732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM AND PS GEAR ASSEMBLY 

    Remove the 4 bolts and front suspension member with lower suspension arm and PS gear assembly.

  16. REMOVE PS GEAR ASSEMBLY 
    1. Remove the stabilizer bar (See REMOVAL ).
    2. Remove the bolt of the rack housing heat insulator.
    3. Remove the 2 bolts, rack housing heat insulator and dynamic damper.
      Fig 5: Removing Front Suspension Member
      G02575733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the column hole cover sub-assembly.
    5. Remove the 4 bolts, nuts and PS gear assembly from the front suspension member.
      NOTE: Because the nut has its own stopper, do not turn the nut and torque the bolt with the nut fixed.
    6. Remove the bracket and grommet from the PS gear assembly.
      Fig 6: Removing Bolts, Nuts And PS Gear Assembly
      G02575734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Place matchmarks on the No. 3 intermediate shaft assembly and control valve shaft.
    8. Remove the bolt and No. 3 intermediate shaft assembly.
  17. REMOVE ENGINE REAR MOUNT INSULATOR AND ENGINE REAR MOUNT BRACKET 
    1. Remove the through bolt, No. 2 engine rear mount bracket and engine rear mount insulator.
    2. Remove the 3 bolts and engine rear mount bracket.
    Fig 7: Placing Matchmarks Intermediate Shaft
    G02575735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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