Toyota 44204-52010
Rack, Front

Secure the manual rack and pinion assembly in a vise using Special Service Tool: 09612-00012 and position it on the vise. Subsequently remove the RH and LH tie rod ends and their lock nuts by marking their locations before loosening the nuts and taking out the parts. Use pliers to pull off RH and LH clips, clamps, and rack boots without damaging them and indicate their placement and orientation. With Service Tool: 09922-10010 engaged firmly on the rack and pinion, use the tool to take away both RH and LH rack ends before unscrewing the rack guide spring cap lock nut. After removing the rack guide spring cap use a screwdriver with vinyl tape to take off the rack guide spring spacer, conical spring washer, rack guide spring, and rack guide sub-assembly before extracting the oil seal spacer and steering pinion. Look for runout, wearing, and damage on the rack and pinion parts with a maximum runout tolerance of 0.15 mm (0.0059 inch). Put Molybdenum Disulfide lithium base grease on designated parts before fitting the rack and pinion at its pinion end and placing the notched side to the pinion location. Use Special Service Tool: 09517-12010 to tap in a new oil seal coated with grease after installing the space and snap ring while pushing the steering pinion. Install the rack guide sub-assembly, rack guide spring, conical spring washer, rack guide spring spacer, and temporarily place the rack guide spring cap on with sealant (Part No. 08833-0080, THREE BOND 1344, LOCTITE 242 or equivalent). You can determine overall preload by adding the RH and LH rack ends temporarily then setting rack guide spring cap torque at 6.9 Nm (70 kgf-cm, 61 inch lbs.) to rotate the pinion shaft before loosening and tightening for a preload range of 0.6 - 1.5 Nm (6 - 15 kgf-cm, 5.2 - 13.0 inch lbs.). Apply the allowed sealant to the rack guide spring cap lock nut (Part No. 08833-0008O) and install it with a total preload of 1.5 Nm (15 kgf-cm) by tightening it to 36 Nm (365 kgf-cm, 26 ft. lbs.) using Special Service Tool: 09922-10010. Install Special Service Tool: 09922-10010 to place the RH and LH rack ends then torque them to 62 Nm (630kgf-cm, 46ft-lbs). Attach RH and LH rack boots followed by clamps and clips before setting the RH and LH tie rod ends properly with lock nuts that need 47 Nm (480kgf-cm, 35ft-lbs) torque and matchmarks alignment.

Temporarily install the right-hand and left-hand rack ends, torque the rack guide spring cap to 6.9 Nm, turn the pinion shaft, loosen the rack guide spring cap until it is non-functional, and then tighten it to achieve a preload of 0.6 - 1.5 Nm.

Remove the front suspension member with lower suspension arm and PS gear assembly by taking out 4 bolts.

Bleed the power steering system, check the steering wheel center point, and torque the steering wheel set nut to 50 Nm.

Hold the RH rack end steady and use Special Service Tool: 09922-10010 to remove the LH rack end, then do the same for the RH rack end.