OEM 2001 Toyota Echo Rack And Pinion

2001 Toyota Echo Parts Questions & Experts Answers

• Q: How to service and repair the Rack And Pinion on 2001 Toyota Echo?

  A: The first step to service and repair the rack and pinion consists of breaking down the unit without applying excessive force to the vise clamp. Service Tool 09023-38200 should be used to remove 2 pressure tubes while extracting the 4 O-rings. The Rack And Pinion assembly must go into a vise using Special Service Tool: 09612-00012. Mark the tie rod ends and rack ends before using a screwdriver to loosen and remove both lock nuts and tie rod ends from each side. Use a screwdriver to gently loosen the clamps before you can remove the clips and clamps along with rack boots while you should mark both rack boots to avoid damaging them. First secure the RH rack end while using Special Service Tool: 09922-10010 to unfasten the LH rack end and later perform the same operation for the RH rack end. The first step involves using Special Service Tool: 09922-10010 to remove the rack guide spring cap lock nut followed by executing removal of the rack guide spring cap then using a 19 mm hexagon wrench for extracting the rack guide spring cap and rack guide spring and rack guide spring spacer and rack guide sub-assembly. To extract the control valve assembly the technician should first mark the housing then remove the two bolts before extracting the complete assembly and its associated gasket. A needle nose plier will help remove the snap ring before extracting the cylinder end stopper. Special Service Tool: 09950-70010 (09951-07200) should be used to push out the rack and pinion with the bushing before removing its O-ring. Special Service Tools 09950-60010 (09951-00240) and 09950-70010 (09951-07360) should be used to press out the oil seal while maintaining the rack housing from damage. The rack and pinion requires a dial indicator inspection for runout along with tooth exam and damage check where a maximum of 0.1 mm (0.004 inch) runout should be present and the needle roller bearing needs examination for replacement decisions about rack housing. Insert the new oil seal with power steering fluid on its lip using Special Service Tools 09950-60010 (09951-00210, 09951-00340, 09952-06010) and 09950-70010 (09951-07100). The installation of the rack and pinion requires the teflon ring and O-ring to be replaced while avoiding damage to the ring groove and a new O-ring needs power steering fluid application before final installation. A new teflon ring must be expanded while receiving power steering fluid treatment before it is positioned onto the rack and pinion. Reassembly requires power steering fluid or molybdenum disulfide lithium base grease coating of indicated parts followed by installing the oil seal into the rack housing using Special Service Tool: 09950-60010 (09951-00210, 09951-00370, 09952-06010), 09950-70010 (09951-07360). Mount the rack and pinion followed by the removal of Special Service Tool: 09631-10041. Application of a power steering fluid coating should be performed before installing the bushing into the rack housing since vinyl tape covering the rack and pinion end prevents oil seal lip damage. Push the cylinder end stopper into place and install the snap ring through the use of needle nose pliers. Test the air tightness of the rack using Special Service Tool: 09631-12071 (09633-00010) by applying 53 kPa (400 mm Hg, 15.75 inch Hg) vacuum for about 30 seconds to check for vacuum fluctuations. Proceed with the installation of fresh control valve gasket material and position the parts using their matchmarks before adding the assembly inside the rack and pinion. Then install both bolts using 21 Nm (220 kgf-cm, 15 ft. lbs.) torque. Round the rack guide sub-assembly together with the rack guide spring spacer, rack guide spring, and rack guide spring cap in a correct spacer position before applying sealant to the rack guide spring cap. Adjust the preload total by first installing rack ends on both sides then torquing the rack guide spring cap to 25 Nm with a return angle of 12 degrees to achieve 1.2 - 1.4 Nm (12 - 14 kgf-cm, 10.4 - 12.2 inch lbs.) preload range. Apply sealant to the locking nut of the rack guide spring cap before tightening it to 28 Nm (290 kgf-cm, 21 ft. lbs.) using Special Service Tool: 09922-10010. Recheck the total preload intensity afterward. Install the RH and LH rack ends at 62 Nm (630 kgf-cm, 46 ft. lbs.) after placing the RH and LH rack boots and clamps with their corresponding clips while ensuring the rack and pinion end hole maintains clearness and using Special Service Tool: 09521-24010. The technician must install both 2-turn pressure tubes with new O-rings that received coating in power steering fluid using Special Service Tool: 09023-38200 and torquing them to 11 Nm (110 kgf-cm, 8 ft. lbs.).