OEM 2002 Toyota Land Cruiser Rack And Pinion

2002 Toyota Land Cruiser Parts Questions & Experts Answers

• Q: How to service and repair the Rack And Pinion on 2002 Toyota Land Cruiser?

  A: The Rack And Pinion assembly needs to be fixed securely with Special Service Tool: 09630-00014 (09631-00142) in a vise while avoiding excess turning pressure. First remove each of the 2-turn pressure tubes through the use of Special Service Tool: 09023-38200 before proceeding to eliminate the tube support retainer bolt and retainer. Use pliers to loosen both clamps and extract the RH and LH clips along with rack boots and clamps while making identifiable marks on the boots to protect them from damage. After staking the washer using a screwdriver and hammer strike the rack and pinion, secure the rack and pinion with Special Service Tool: 09922-10010 to remove the rack end while marking the RH and LH rack ends. Start by loosening the rack guide spring cap lock nut as you move to remove the rack guide spring cap, then rack guide spring together with rack guide sub-assembly before removing the dust cover. To access the control valve housing and assembly use matchmarks before removing its two bolts so you can pull out the assembly and retrieve the housing O-ring. First loosen the bearing guide nut using Special Service Tool: 09631-20060 then wind vinyl tape on the control valve shaft before tapping out the valve assembly with the bearing guide nut while being careful to avoid damaging the oil seal lip. The cylinder end stopper and spacer can be removed with Special Service Tool: 09922-10010 after its O-ring has been extracted from the stopper. The rack and pinion undergoes press-out operation with Special Service Tool: 09950-70010 (09951-07200) which requires keeping the rack securely mounted to avoid any drops and followed by oil seal extraction from the rack. The process requires Special Service Tool: 09950-60010 (09951-00360), 09950-70010 (09951-07360) to extract both components. Maximal runout of the rack and pinion should not exceed 0.03 mm (0.0118 inch) while inspecting for wear and runout of both components. Check the bearing for damage and apply molybdenum disulfide lithium base grease to required areas. Make the replacement of oil seal and bearing using Special Service Tool: 09950-60010 (09951-00260), 09950-70010 (09951-07150), taking care to install the oil seal in its proper installation direction. Replace cracked bushings while applying grease to their inner cavity. Fitting Special Service Tool: 09631-20081 to slid new rings onto the control valve assembly before installing the Teflon ring and O-ring to the rack and pinion section while avoiding damaging the ring groove. The control valve housing may require replacement of its union seat when necessary. Installation for reassembly starts with applying power steering fluid or molybdenum disulfide lithium base grease to the parts before placing the spacer along with the oil seal in correct orientation while rack and pinion installation requires Special Service Tool: 09631-00350. Using Special Service Tool: 09922-10010 torque the cylinder end stopper until it reaches a torque of 66 Nm (670 kgf-cm, 48 ft. lbs.). Test the air tightness with Special Service Tool: 09631-12071 under vacuum pressure of 53 kPa (400 mmHg, 15.75 inch Hg) during a 30 second observation period. Fasten the control valve assembly by first applying Teflon rings with protective coating to the oil seal lip and then securing the bearing guide nut to 25 Nm (250 kgf-cm, 18 ft. lbs.) before staking the nut. The control valve housing should be fitted with the valve assembly while aligning matchmarks then torquing bolts to 18 Nm (180 kgf-cm, 13 ft. lbs.). You should apply sealant to threads before installing the dust cover and rack guide sub-assembly together with the rack guide spring and rack guide spring cap. Total preload adjustment requires a temporary installation of RH and LH rack ends followed by rack guide spring cap torquing to 25 Nm (250 kgf-cm, 18 ft. lbs.) with the cap positioned at 19 degrees. Special Service Tool: 09616-00011 with its probe assembly should be used to set the preload within 1.3 - 1.8 Nm (13.3 - 18.4 kgf-cm or 11.5 - 16.0 inch lbs.). Proceed with installing the rack guide spring cap lock nut which received sealant treatment before torquing it to 51 Nm (520 kgf-cm, 38 ft. lbs.) using Special Service Tool: 09922-10010. Total preload should be rechecked after lock nut installation. The installation process concludes with tightening the rack end to 76 Nm (770 kgf-cm, 56 ft. lbs.) using Special Service Tool: 09922-10010 while staking the washer before adding the RH and LH rack boots and clamps along with their clips and verifying the tube hole remains clear and the boot remains undamaged. Fasten the tube support retainer through its bolt before final tightening to 19 Nm (195 kgf-cm, 14 ft. lbs.) and fully install the 2 turn pressure tubes by tightening them to 23 Nm (230 kgf-cm, 17 ft. lbs.).