Toyota 44204-17060
Rack Assembly, Front

A proper repair or servicing of rack and pinion starts by removing parts without clamping them too tightly into the vise. Apply Special Service Tool: 09023-38200 to eliminate the 2 turn pressure tubes from the system before removing the 4 O-rings. Secure the Rack And Pinion assembly into Special Service Tool: 09612-00012 placed within a vise. Begin rack and pinion service by removing the RH and LH tie rod ends and their lock nuts before proceeding to detach the clips and clamps and rack boots while protecting the boots from harm. The LH rack end requires stability while using the Special Service Tool: 09922-10010 to extract the RH rack end followed by the LH rack end removal procedure. First detach the rack guide spring cap lock nut with Special Service Tool 09922-10010, then proceed to remove the rack guide spring cap followed by the rack guide spring while using a 19 mm hexagon wrench. The removal process starts by taking out the rack housing cap and self-locking nut through the usage of Special Service Tool: 09616-00011. Extract the control valve housing and its internal control valve piece once you remove the dust seal and properly tag the housing components. Protect the control valve assembly oil seal lip as you press out the assembly using tape wrapped around the valve shaft. Take the control valve assembly oil seal out followed by using needle nose pliers to remove the snap ring after which pull out the cylinder end stopper. The bushing holding the rack and pinion needs to be pressed out using Special Service Tool 09950-70010 (09951-07200) to extract its O-ring. Check the rack and pinion for any runout exceeding 0.1 mm (0.004 inch) and also inspect for wear and damage to its teeth. To install a new rack housing oil seal use Special Service Tool: 09950-60010 (09951-00210, 09951-00240, 09952-06010). The lip of this new oil seal requires power steering fluid coating before installation. Use Special Service Tool: 09950-60010 (09951-00260) to install a new control valve housing oil seal before facing it correctly toward its installation direction. To replace the no. 1 and no. 2 bearings of the rack housing users need proper tools and should use appropriate grease. The rack and pinion bushing requires removal of the oil seal using Special Service Tool: 09612-24014 (09613-22011) before entering a new oil seal. Replace the teflon ring and O-ring of the rack and pinion while avoiding damaging the ring groove before installing new teflon rings into the control valve assembly. Reassemble parts using power steering fluid or molybdenum disulfide lithium base grease, then install the rack and pinion together with bushing and use Special Service Tool: 09631-12071 (09633-00010) for air tightness testing. The installation should begin with proper alignment of the control valve assembly together with the oil seal and new gasket before torquing according to specifications. The assembly requires installation of a self-locking nut alongside a rack housing cap containing sealant followed by the rack guide sub-assembly. Total preload needs adjustment according to specifications. Complete the installation by adding the rack guide spring cap lock nut, installing the RH and LH rack ends and installing turn pressure tubes equipped with new O-rings while following all torque values.

Torque to 22.5 Nm (230 kgf-cm, 17 ft. lbs.) with a torque wrench of 345 mm (13.58 inch) fulcrum length.

Install the steering wheel pad, tool box, and luggage compartment trim box cover.

Take out the 2 bolts, 2 nuts, and 4 plate washers from the steering gear support member.

Loosen the clamp with a screwdriver to remove the clip, clamp, and rack boot, ensuring not to damage the boot, and mark the RH and LH rack boots.

Install the self-locking nut to 24.5 Nm (250 kgf-cm, 18 ft. lbs.) and the rack housing cap with sealant to 59 Nm (600 kgf-cm, 43 ft. lbs.), staking the cap afterward.

Remove the luggage compartment trim box cover and the tool box.