Toyota 45510-12471
Gear Assembly

The first step to remove the power rack and pinion requires placing the front wheels in a straight position while securing the steering wheel with a seat belt to prevent spiral cable damage. To start the process first remove the column hole cover silencer sheet followed by separating the No. 2 rack and pinion intermediate shaft assembly and then detach the No. 1 rack and pinion hole cover sub-assembly by removing clip A and detaching clip B from the body. The technician should first detach the front wheels alongside No. 1 engine under cover and No. 2 engine under cover and rear engine under covers LH and RH and front suspension member reinforcements LH and RH from both sides. The necessary tool 09960-20010 will separate the tie rod end from the rack and pinion knuckle but you should ensure correct alignment and secure the tool to stop tools from dropping. The technician should first detach front lower suspension arm sub-assemblies LH and RH from the vehicle and then take out the front suspension member rear braces LH and RH followed by removal of the front suspension crossmember sub-assembly. Then remove the bolt from the rack and pinion link assembly followed by both matchmarks on the rack and pinion intermediate shaft and rack and pinion link assembly. Afterward detach the rack and pinion hole cover sub-assembly from the rack and pinion link assembly. Separate the rack and pinion link assembly by undoing its 2 bolts with 2 nuts but do not rotate the nut when breaking the bolt then clamp the rack and pinion link assembly into a vise using Special Service Tool: 09612-00012 to finally remove the tie rod end sub-assemblies LH and RH while making notes for later reinstallation.

The first step for power steering rack and pinion removal begins by positioning the front wheels straight ahead followed by securing the steering wheel with a seat belt to stop rotation for protecting the spiral cable structure. Newbie technicians should start by taking away the silencer sheet from the column hole cover then split the No. 2 rack and pinion intermediate shaft assembly before detaching the No. 1 rack and pinion column hole cover sub-assembly by unfastening clip A while detaching clip B without causing damage to the components. The technician needs to follow identical procedures to extract both front wheels as well as the No. 1 engine under cover, No. 2 engine under cover, rear engine under covers LH and RH, and front suspension member reinforcements LH and RH. Next proceed with front stabilizer link assembly separation of both the LH and RH sides followed by tie rod end sub-assembly dissociation of LH and RH components. Perform this operation by removing the cotter pin and nut then align the tie rod end upper ends using Special Service Tool: : 09960-20010 and Special Service Tool: : 09960-20010 09961-02010 to disconnect the tie rod end from the rack and pinion knuckle while maintaining protection of the front disc brake dust cover along with ball joint dust cover and rack and pinion knuckle themselves. Among the procedures are front lower suspension arm sub-assembly separation of LH and RH followed by front suspension member rear brace removal of LH and RH components and front suspension crossmember sub-assembly extraction. Before the operation continue with the following procedure: first disconnect the bolt and rack and pinion intermediate shaft while placing matchmarks on the combination of the rack and pinion link assembly and rack and pinion intermediate shaft. The rack and pinion link assembly requires removal by first uninstalling its two bolts and two nuts while securing the assembly inside a vise with Special Service Tool: 09612-00012 and imposing tape protection before use. Finally, remove the tie rod end sub-assemblies LH and RH, maintaining alignment markings.

Proceed to install the front suspension crossmember sub-assembly, followed by the front suspension member rear brace LH and RH, using the same procedure for both sides.

Install the No. 2 steering intermediate shaft assembly and the column hole cover silencer sheet, then install the front wheels, torquing to 103 Nm (1050 kgf-cm, 76 ft-lbf), and inspect and adjust the front wheel alignment.

Remove the cotter pin and nut, install Special Service Tool: 09960-20010 to the tie rod end, ensuring alignment with the upper ends, and use Special Service Tool: 09960-20010 09961-02010 to separate the tie rod end from the steering knuckle.