Toyota Tacoma 2002-06

Removal & Installation

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Fig. Power steering gear and related components-2WD 2001-2004



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Fig. Power steering gear and related components-4WD 2001-2004

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right and left tie rod ends from the knuckle
     
    Intermediate No. 2 shaft from the steering rack
     
    Pressure feed and the return tubes, using SST 09631-22020
     
    Power steering rack
     

  4.  

To install:

  1. Install the power steering rack. Tighten the bolts to 148 ft. lbs. (201 Nm) for 2WD or to the following values for 4WD:

    Rack assembly bolt: 123 ft. lbs. (167 Nm)
     
    Rack assembly nut: 141 ft. lbs. (191 Nm)
     
    Bracket nut and bolt: 123 ft. lbs. (167 Nm)
     

  2.  
  3. Install or connect the following:

    New O-ring
     
    Pressure feed tube. Tighten it to 33 ft. lbs. (45 Nm).
     
    Return tube. Tighten it to 36 ft. lbs. (49 Nm) for 2WD or to 29 ft. lbs. (40 Nm) for 4WD
     
    Intermediate No. 2 shaft to the steering rack
     
    Right and left tie rod ends to the steering knuckle
     
    Tighten the castle nuts to specification
     
    New cotter pins
     
    Negative battery cable
     

  4.  
  5. Check the steering wheel center point.
  6.  
  7. Bleed the power steering system.
  8.  
  9. Check the front wheel alignment. Tighten the tie rod end locknuts to 67 ft. lbs. (90 Nm)
  10.  

2-Wheel Drive





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Fig. Power steering gear and related components-2WD 2005-2006

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Position the front wheels in the straight ahead position.
  4.  
  5. Disconnect the negative battery cable. Drain the power steering fluid.
  6.  
  7. Raise and support the vehicle safely. Remove the tire and wheel assemblies.
  8.  
  9. Lock the steering wheel to prevent it from turning.
    NOTE
    The seat belt can be used to prevent rotation.

  10.  
  11. Place matchmarks on the steering slider yoke, the steering intermediate shaft number two and the steering intermediate shaft.
  12.  
  13. Remove the steering slider yoke bolts. Slide the steering sliding yoke up and separate it from the steering intermediate shaft number two.
  14.  
  15. Pull down the steering sliding yoke from the steering intermediate shaft and remove it.
  16.  
  17. Place matchmarks on the steering intermediate shaft number two and the power steering gear.
  18.  
  19. Remove the bolt from the steering intermediate shaft number two.
  20.  
  21. Slide the steering intermediate shaft number two up and remove it from the power steering gear.
  22.  
  23. Remove the cotter pin and nut. Using tool SST09610-20012 or equivalent, separate the left tie rod end from the left steering knuckle arm.
  24.  
  25. Remove the cotter pin and nut. Using tool SST09610-20012 or equivalent, separate the right tie rod end from the right steering knuckle arm.
  26.  
  27. Remove the bolt and separate the tube support bracket. Separate the pressure line. Disengage the clip and disconnect the return hose.
  28.  
  29. Remove the power steering gear retaining bolts. Remove the steering gear from the vehicle.
    NOTE
    The nut has a detent, so never turn it. Always turn the bolt.

  30.  

To install:

  1. Install the power steering gear. Tighten the retaining bolts to 68 ft. lbs.
    NOTE
    The nut has a detent, so never turn it. Always turn the bolt.

  2.  
  3. Continue the installation in the reverse order of the removal procedure.
  4.  
  5. Be sure to fill the power steering system with the proper grade and type power steering fluid.
  6.  
  7. Bleed the system, as required.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  
  11. Check and adjust the alignment, as required.
  12.  

4-Wheel Drive





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Fig. Power steering gear and related components-4WD and PreRunner 2005-2006

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Position the front wheels in the straight ahead position.
  4.  
  5. Disconnect the negative battery cable. Drain the power steering fluid.
  6.  
  7. Raise and support the vehicle safely. Remove the tire and wheel assemblies.
  8.  
  9. Remove the number one engine undercover subassembly.
  10.  
  11. Remove the front exhaust pipe assembly. On the 4.0L engine, remove the number two exhaust pipe assembly.
  12.  
  13. Remove the driveshaft. Some vehicles also use a center bearing assembly, remove that too.
  14.  
  15. Remove the frame crossmember subassembly.
  16.  
  17. Remove the stabilizer bar.
  18.  
  19. Lock the steering wheel to prevent it from turning.
    NOTE
    The seat belt can be used to prevent rotation.

  20.  
  21. Place matchmarks on the steering slider yoke, the steering intermediate shaft number two and the steering intermediate shaft.
  22.  
  23. Remove the steering slider yoke bolts. Slide the steering sliding yoke up and separate it from the steering intermediate shaft number two.
  24.  
  25. Pull down the steering sliding yoke from the steering intermediate shaft and remove it.
  26.  
  27. Place matchmarks on the steering intermediate shaft number two and the power steering gear.
  28.  
  29. Remove the bolt from the steering intermediate shaft number two.
  30.  
  31. Slide the steering intermediate shaft number two up and remove it from the power steering gear.
  32.  
  33. Remove the cotter pin and nut. Using tool SST09610-20011 or equivalent, separate the left tie rod end from the left steering knuckle arm.
  34.  
  35. Remove the cotter pin and nut. Using tool SST09610-20011 or equivalent, separate the right tie rod end from the right steering knuckle arm.
  36.  
  37. Remove the bolt and separate the tube support bracket. Separate the pressure line. Disengage the clip and disconnect the return hose.
  38.  
  39. Remove the power steering gear retaining bolts. Tilt the transmission and remove the steering gear from the vehicle.
    NOTE
    The nut has a detent, so never turn it. Always turn the bolt.

  40.  

To install:

  1. Install the power steering gear. Tighten the retaining bolts to 68 ft. lbs.
    NOTE
    The nut has a detent, so never turn it. Always turn the bolt.

  2.  
  3. Continue the installation in the reverse order of the removal procedure.
  4.  
  5. Be sure to fill the power steering system with the proper grade and type power steering fluid.
  6.  
  7. Bleed the system, as required.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  
  11. Check and adjust the alignment, as required.
  12.  

 
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