OEM 2001 Toyota 4Runner Rack And Pinion

2001 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to disassemble the Rack And Pinion on 2001 Toyota 4Runner?

  A: Disassembly of the rack and pinion begins by utilizing Special Service Tool: 09023-38200 to remove the 2 turn pressure tubes and afterwards extracting the 4 union seats from both the rack housing and control valve housing. Secure the assembly to a vise by using Special Service Tool: 09612-00012 with two bolts (Bolt: 90105-10346 and Nut: 90170-10198). Identify the tie rod ends lock nuts and rack end before slowly loosening both right and left locknuts. Afterwards take away the RH and LH clips and rack boots and clamps by avoiding damage to the boots. Using a screwdriver and hammer and a spanner you can remove the hollow claw washers from the rack and pinion while marking the Right Hand and Left Hand ends using Special Service Tool: 09922-10010. Start by unscrewing the rack guide spring cap lock nut followed by the removal of the rack guide spring cap. Proceed with taking out the rack guide spring and the rack guide until finally removing the dust cover. The procedure to remove the control valve housing with control valve assembly requires marking matchmarks followed by disassembling 2 bolts to pull out the assembly. The O-ring inside the rack housing should also be removed. Using Special Service Tool: 09631-20060 to loosen the bearing guide nut allows you to wrap vinyl tape around the control valve shaft before using a plastic hammer to tap out the control valve assembly with great care for the oil seal lip. Press out the rack and pinion and oil seal with Special Service Tool: 09950-70010 (09951-07360) after removing the cylinder end stopper along with its O-ring through Special Service Tool: 09922-10010 but be sure not to allow the rack to fall. You should use Special Service Tool: 09950-60010 (09951-00360), 09950-70010 (09951-07360) for pressing out the oil seal and spacer. Inspection of the rack and pinion must check for runout of 0.03mm (0.0118inch) while assessing needle roller bearing damage to decide whether the rack housing requires replacement. Inject molybdenum disulfide lithium base grease inside the bearing then inspect its rotating noise for any damage to the control valve assembly. To perform the replacement of the oil seal and bearing utilize Special Service Tool: 09950-60010 (09951-00260), 09950-70010 (09951-07150) while applying power steering fluid to the new oil seal lip before using Special Service Tool: 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150). The bushing needs inspection for cracks and you should apply grease if needed while replacing it with a new part. A screw extractor will remove the union seats which should be gently tapped into place with a plastic hammer. The process for bearing guide nut oil seal replacement requires Special Service Tool: 09950-60010 (09951-00320), 09950-70010 (09951-07100). Before installation press the new oil seal into place with care while the lip is coated with power steering fluid. Reposition the 4 teflon rings from the control valve assembly then expand new rings while applying power steering fluid before installing them precisely. During reassembly threads should be coated either with power steering fluid or molybdenum disulfide lithium base grease while proper orientation of the spacer and oil seal must be maintained for installation of the rack and pinion using Special Service Tool: 09631-00350. Push the oil seal onto the tool while avoiding tilting and mount the cylinder end stopper, using a new O-ring before tightening it to 58 Nm (590 kgf-cm, 43 ft. lbs.). Apply a 30-second vacuum test through Special Service Tool: 09631-12071 under 53 kPa (400 mm Hg, 15.75 inch Hg) pressure to check for air tightness. Change direction of the control valve assembly into the housing while applying power steering fluid to teflon rings and carefully handle the oil seal lip to prevent damage. The technician installs the bearing guide nut using Special Service Tool: 09631-20060 after torquing it to 25 Nm (250 kgf-cm, 18 ft. lbs.) followed by staking the nut. Secure the control valve housing through the assembly process where matchmarks should align before torquing the bolts to 18 Nm (180 kgf-cm, 13 ft. lbs.). Use sealant to apply it to threads of the rack guide spring cap and dust cover before final installation. The adjustment of total preload requires the rack end installation for a brief period followed by rack guide spring cap tightening to 25 Nm (250 kgf-cm, 18 ft. lbs.) until the cap returns to 19 degrees. Total preload should be adjusted using Special Service Tool: 09616-00011 to 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.). Install the rack guide spring cap lock nut which contains sealant and torque it to 51 Nm (520 kgf-cm, 38 ft. lbs.) before rechecking the total preload. Install the RH and LH rack ends followed by rail boots and clamps with clear tube holes and secured clamps before torquing the RH and LH tie rod ends to 55 Nm along with the 2 turn pressure tubes with Special Service Tool: 09023-38200 to a torque setting of 23 Nm.