OEM 2002 Toyota Celica Rack And Pinion

2002 Toyota Celica Parts Questions & Experts Answers

• Q: How to disassemble the Rack And Pinion on 2002 Toyota Celica?

  A: The tool set of Special Service Tool: 09612-00012 and 09023-38200 should be used to secure the Rack And Pinion assembly in a vise before the tool set removes the 2 turn pressure tubes. The first step is to mark the tie rod end and rack end before lightly loosening the lock nut. Both tie rod ends and lock nuts should then be removed from their sides. Through needle nose plier usage, you should carefully free the wire and remove the boot and clip along with the wire. Ensure you protect the boot and label the RH and LH rack boots. Use a chisel and hammer to unstake the claw washer while safeguarding the rack and pinion from damage and apply a spanner to support the rack before removing the end with Special Service Tool: 09922-10010 to mark and detach both LH and RH rack ends and the claw washer. The service technician should remove the rack guide spring cap which leads to extraction of conical spring washer and rack guide sub-assembly then continues with rack housing cap and O-ring. The control valve assembly requires pull-out along with the necessary caution to keep the oil seal lip undamaged for continued safety. The cylinder end stopper requires removal using snap ring pliers to complete the process. Use Special Service Tool: 09950-70010 (09951-07200) to press out the rack and pinion and oil seal from their positions without allowing the rack and pinion to drop. Special Service Tools: 09950-60010 (09951-00280), 09950-70010 (09951-07360) will help press out the oil seal by protecting the rack housing from potential damage. Use a dial indicator to examine the rack and pinion for runout and inspect teeth wear as well as damage. The maximum acceptable runout should be 0.1 mm (0.004 inch) while an examination of the back surface for signs of wear or damage should also be performed. To replace the bearing use Special Service Tool: 09617-35020 for bearing guide nut and bearing removal. Apply molybdenum disulfide lithium base grease to a new bearing and torques the guide nut to 40 Nm (410 kgf-cm, 30 foot lbs.). Installation of a new oil seal needs screwdriver use with vinyl tape to remove the old component followed by fluid coating the new seal lip and pressing it in with Special Service Tool: 09950-60010 (09951-00210, 09951-00340, 09952-06010), 09950-70010 (09951-07100) for correct orientation. The new oil seal follows a replacement procedure using Special Service Tool: 09612-20010 and requires steering fluid coating of the lip before insertion with Special Service Tool: 09950-60010 (09951-00240, 09951-00350, 09952-06010), 09950-70010 (09951-07150) and a hammer. The procedure requires removal of the bearing using punch and hammer before treating a new bearing with grease then installing it using brass bar and hammer. When replacing old union seats start by extracting the old ones with a screw extractor followed by gently installing new ones after cleaning the rack housing. When changing the parts begin by extracting the old Teflon ring and O-ring using a screwdriver followed by O-ring coating in power steering fluid and proper installation then establish the new Teflon ring by fluid coating followed by appropriate placement. The procedure for control valve assembly involves removing 4 Teflon rings and expanding new ones before fluid coating them and installing them with precise application of Special Service Tool: 09631-20081. Install new parts by brushing power steering fluid or grease onto them before positioning them correctly with the oil seal set up in the right orientation and prevent any part reversal. First install the rack and pinion through Special Service Tool: 09631-20051 and then apply fluid during installation before removing the tool. Embed the oil seal inside the rack housing by avoiding any tilting motion and maintaining its correct placement before installing the cylinder end stopper through Special Service Tool: 09612-22011 with a hammer as well as a new snap ring. Test the air tightness using Special Service Tool: 09631-12071 by applying a 53 kPa (400 mmHg, 15.75 inch Hg) vacuum for 30 seconds followed by leakiness checks. After checking for any harm to Teflon rings and oil seal lips, install the control valve assembly before installing the rack housing cap with a fresh O-ring that received fluid treatment then torque it to 74 Nm (750 kgf-cm, 54 ft. lbs.). Fasten the rack guide sub-assembly together with a conical spring washer while using sealant on the threads of the rack guide spring cap. To adjust total preload install both RH and LH rack ends temporarily while torquing the rack guide spring cap to 25 Nm (250 kgf-cm, 18 ft. lbs.) and returning it 12° before using Special Service Tool: 09616-00011 to turn the control valve shaft. Slightly rotate the rack guide spring cap until the spring stops operating then retighten it for a preload between 0.9 to 1.3 Nm (9 to 13 kgf-cm, 8.0 to 11.5 inch lbs.) followed by staking and checking preload once again. To proceed replace the RH and LH rack ends along with installing new claw washers and rack ends before connecting them properly to the rack and pinion grooves then torque the rack end to 62 Nm (630 kgf-cm, 46 ft. lbs.) using Special Service Tool: 09922-10010. The installation process includes fitting both rack boot sections, wires, and clips but requires the rack and pinion opening free of obstruction before completing wire tensioning around the boot area. Follow the process of aligning matchmarks on the rack end before adjusting toe-in and tightening the lock nut to 74Nm (750kgf-cm, 54ft. lbs.). Then complete the procedure by installing the 2-turn pressure tubes using Special Service Tool: 09023-38200 and torquing them to 23Nm (230kgf-cm, 17ft. lbs.).