Reassembly (RAV4)
- With rack housing mounted vertically in soft-jaw vise, coat NEW seal with power steering fluid, and press into rack housing from end opposite control valve housing portion. See Figure. Ensure oil seal faces in proper direction.
- Mount rack housing horizontally in vise. Clean rack teeth of any burrs. Place protective end piece on steering rack teeth end. Coat protective sleeve with power steering fluid. Install steering rack into rack housing. Remove protective sleeve.
- Coat NEW oil seal lip with power steering fluid. Wrap tape on end of steering rack (opposite of control valve housing end). Push oil seal evenly into rack housing. See Figure.
- Install end stopper into rack housing. Install NEW snap ring.
- Install special connectors onto union fittings of rack housing, and attach hand vacuum pump. Apply 15.75" Hg for about 30 seconds. Ensure there is no vacuum leak. If leak exists, check installation of oil seals at each end of housing. See Fig 1.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Coat Teflon rings with power steering fluid. Install control valve assembly into rack housing. Press NEW bearing into place on top of control valve. Press NEW oil seal into place after coating lip with power steering fluid. Install NEW snap ring. See Figure. Install dust cover.
- Press NEW bearing into lower side of rack housing. Install lock nut onto lower end of control valve assembly. Tighten to specification. See TORQUE SPECIFICATIONS . Using installer tool, box wrench and crescent wrench, turn "C" to set dimension "A" to .65-.67" (16.5-17.0 mm). Stake nut by turning part "B" until it touches spacer of installer tool. See Fig 2.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Apply thread lock sealant to 2-3 threads of rack housing cap. Install and tighten cap to specification. See TORQUE SPECIFICATIONS .
- Install rack guide seat to guide. Install guide, spring, washer and cap. Temporarily tighten cap.
- Temporarily install both rack ends. Using 21-mm wrench, tighten rack guide spring cap to 18 ft. lbs. (24 N.m). Loosen cap by 12 degrees. Using torque wrench on top end of control valve stem, turn stem right and left 1-2 times. Using 21-mm wrench, loosen rack guide spring cap until rack guide spring is not functioning. Tighten control valve stem and rack guide spring cap until preload is within 6.9-11.3 INCH lbs. (0.8-1.3 N.m), measured with torque wrench on control valve stem. See Fig 3.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Apply thread lock sealant to rack guide spring cap lock nut. Using 21-mm wrench to hold spring cap from rotating, use torque wrench to tighten lock nut to specification. See TORQUE SPECIFICATIONS . Recheck preload.
- Remove both rack ends. Install NEW claw washers on each end of rack. Align claws with grooves in rack. Install rack ends. Hold rack from turning and tighten rack ends to 44 ft. lbs. (60 N.m). Stake claw washers.
- Install grommet in rack housing mounting bracket No. 1. Align reference marks, and install bracket. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .
- Ensure steering rack hole (next to rack end) is not clogged with grease. Clean as necessary. Install boots, clamps and clips. Tighten clamp bolts until there is .08" (2.0 mm) clearance between clamp ends.
- Screw tie rod end lock nut onto tie rod until reference marks are aligned. Install left and right tie rod ends. After adjusting toe-in, tighten lock nuts to specification. See TORQUE SPECIFICATIONS .
- Install 2 turn pressure tubes. Use NEW gaskets on union fittings. Tighten fittings to specification. See TORQUE SPECIFICATIONS .