Steering Gear Disassembly

Steering. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
Steering Gear Linkage. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. REMOVE STEERING TURN PRESSURE TUBE

  2. SECURE POWER STEERING LINK ASSEMBLY

  3. REMOVE TIE ROD END SUB-ASSEMBLY LH

  4. REMOVE TIE ROD END SUB-ASSEMBLY RH

  5. REMOVE STEERING RACK BOOT CLAMP LH

  6. REMOVE STEERING RACK BOOT CLAMP RH

  7. REMOVE STEERING RACK BOOT CLIP LH

  8. REMOVE STEERING RACK BOOT CLIP RH

  9. REMOVE STEERING RACK BOOT LH

  10. REMOVE STEERING RACK BOOT RH

  11. REMOVE STEERING RACK END SUB-ASSEMBLY

  12. REMOVE RACK GUIDE

  13. REMOVE POWER STEERING CONTROL VALVE

  14. REMOVE CYLINDER END STOPPER

  15. REMOVE POWER STEERING RACK AND OIL SEAL

  16. INSPECT POWER STEERING RACK

  17. REMOVE "TEFLON" RING

  18. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL

Steering Gear -- Disassembly


NOTICE:
  1. When using a vise, place aluminum plates between the part and vise.
  2. When using a vise, do not overtighten it.
HINT:
  1. Use the same procedure for RHD and LHD vehicles.
  2. The procedure listed below is for LHD vehicles.


1. REMOVE STEERING TURN PRESSURE TUBE

  1. Using a union nut wrench, remove the 2 turn pressure tubes.

  1. Remove the 4 O-rings.



2. SECURE POWER STEERING LINK ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using SST, secure the steering link between aluminum plates in a vise, as shown in the illustration.

    SST
    09612-00012


3. REMOVE TIE ROD END SUB-ASSEMBLY LH


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Place matchmarks on the tie rod end, lock nut and rack end.

    Text in Illustration
    *1
    		Matchmark

  1. Loosen the lock nut and remove the tie rod end and lock nut.



4. REMOVE TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedure described for the LH side.


5. REMOVE STEERING RACK BOOT CLAMP LH


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Using pliers and a screwdriver, remove the clamp.

    NOTICE:
    Be careful not to damage the boot.


6. REMOVE STEERING RACK BOOT CLAMP RH
HINT:
Use the same procedure described for the LH side.


7. REMOVE STEERING RACK BOOT CLIP LH

  1. Using pliers, remove the clip.

    NOTICE:
    Be careful not to damage the boot.


8. REMOVE STEERING RACK BOOT CLIP RH
HINT:
Use the same procedure described for the LH side.


9. REMOVE STEERING RACK BOOT LH


10. REMOVE STEERING RACK BOOT RH


11. REMOVE STEERING RACK END SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using a screwdriver and hammer, unstake the washers.

    NOTICE:
    Do not strike the steering rack.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using a wrench, hold the steering rack (LH side).

    Text in Illustration
    *A
    		for RH Side
    *B
    		for LH Side
    *1
    		Wrench
    *a
    		Hold
    *b
    		Turn

  1. Using SST, remove the steering rack end (LH side) from the power steering rack.

    SST
    09922-10010
    HINT:
    Rotate SST in the direction shown in the illustration.

  1. Using SST, remove the steering rack end (RH side) from the power steering rack.

    SST
    09922-10010
    HINT:
    Rotate SST in the direction shown in the illustration.

  1. Remove the 2 claw washers.



12. REMOVE RACK GUIDE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using SST, remove the lock nut.

    SST
    09922-10010


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using a 12 mm socket wrench, remove the rack guide spring cap.

    Text in Illustration
    *1
    		12 mm Socket Wrench

  1. Remove the spring and rack guide.



13. REMOVE POWER STEERING CONTROL VALVE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Remove the 2 bolts.

  1. Pull out the control valve from the rack housing.

  1. Remove the control valve gasket.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using a screw extractor, remove the 2 union seats from the control valve housing.

    Text in Illustration
    *1
    		Screw Extractor


14. REMOVE CYLINDER END STOPPER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using SST, remove the stopper.

    SST
    09631-20120


15. REMOVE POWER STEERING RACK AND OIL SEAL


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Using SST, press out the steering rack and oil seal.

    SST
    09950-70010(09951-07200)
    NOTICE:
    Take care not to drop the steering rack.

  1. Remove the oil seal from the steering rack.

  1. Remove the bush from the steering rack.



16. INSPECT POWER STEERING RACK


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Insert a wire 20 mm (0.787 in.) into the vent hole of the steering rack and make sure that the vent hole is not clogged with grease.

    NOTICE:
    If the hole is clogged, the pressure inside the boot will change after the boot is assembled and the steering wheel is turned.


17. REMOVE "TEFLON" RING

  1. Using a screwdriver, remove the "Teflon" ring and O-ring from the steering rack.

    NOTICE:
    Be careful not to damage the groove of the ring.


18. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Install SST (09612-07120) to SST (09612-07210).

    SST
    09612-70100(09612-07120,09612-07210)
    NOTICE:
    1. Lightly apply MP grease to the tip of SST (09612-07230) and inside of SST (09612-07210 and 09612-07120) before use.
    2. Completely install SST (09612-07120) to SST (09612-07210) to prevent damage to the inside of the rack housing.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Insert SST (09612-07210) into the rack housing at an angle until it comes in contact with the power steering cylinder tube oil seal. Install SST (09612-07220) to SST (09612-07210).

    SST
    09612-70100(09612-07120,09612-07210,09612-07220)
    NOTICE:
    Do not damage the inside of the power steering rack housing.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Hold SST (09612-07220) and pull SST (09612-07210) to position SST (09612-07120) inside of the rack housing.

    SST
    09612-70100(09612-07120,09612-07210,09612-07220,09612-07230)
    HINT:
    Make sure that SST (09612-07120) is positioned at the chamfered part between the power steering cylinder tube oil seal and the rack housing.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Install SST (09612-07240) to SST (09612-07230). Insert the tip of SST (09612-07230) into the service hole of SST (09612-07120) in the rack housing.

    SST
    09612-70100(09612-07120,09612-07230,09612-07240)
    NOTICE:
    1. Make sure that SST (09612-07240) is installed to prevent damage to SST (09612-07120).
    2. Do not damage the inside of the rack housing.


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Steering Gear Linkage.Steering Gear.Steering Gear Disassembly

  1. Install SST (09951-07150) to SST (09612-07230). Using a press, remove the power steering cylinder tube oil seal.

    SST
    09612-70100(09612-07120,09612-07230,09612-07240)
    09950-70010(09951-07150)
    NOTICE:
    Do not damage the rack housing.
    HINT:
    Replace SST (09951-07150) with another of different length from the set if necessary.