OEM 2002 Toyota RAV4 Rack And Pinion

2002 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to disassemble the Rack And Pinion on 2002 Toyota RAV4?

  A: The rack and pinion disassembly process starts by taking out the 2 turn pressure tubes using SST 09023-38200 followed by installing the Rack And Pinion assembly inside SST 09612-00012. Use matchmarks to prepare the RH and LH tie rod ends and lock nuts before loosening the lock nuts on the second side. Detach the clamp screw to release both RH and LH clips together with their clamps and rack boots without causing boot damage. Use the screwdriver with hammer to unstake the claw washer before removing the rack end by gripping the rack and pinion with a 22 mm spanner and using SST 09922-10010. The first step involves removing both the rack housing bracket with grommet from No. 1 position along with the rack guide spring cap lock nut through the use of SST 09922-10010. A 21 mm hexagon wrench can be used to remove the rack guide spring and the rack guide spring cap while also removing conical spring and rack guide spring. Use SST 09616-00011 to remove both the rack housing cap and self-locking nut before taking out the control valve assembly, upper oil seal and upper bearing by using snap ring plier SST 09613-12010. A brass bar enables users to remove the cylinder end stopper and the rack and pinion with its oil seal. The rack and pinion requires an inspection for runout and teeth wear together with damage evaluation while checking control valve assembly and bushing dimensions. Replace the lower bearing within the rack housing by first greasing it with molybdenum disulfide lithium base grease before installation. The technicians will accomplish this task by conducting the following steps: press out the oil seal with SST 09950-60010 (09951-00260, 09951-00400, 09952-06010, 09951-00230 or 09951-00350, 09952-06010) and SST 09950-70010 (09951-07360) while coating the new oil seal lip with power steering fluid before pressing it into place. SST 09612-24014 (09613-22011) should be used to remove the bushing followed by tapping out the oil seal then coating a new oil seal lip with power steering fluid while using SST 09950-60010 (09951-00280, 09951-00350, 09952-06010), 09950-70010 (09951-07150) for pressing it in. SST 09630-24014 (09631-24031) should be used to install a new Teflon ring after coating the O-ring with power steering fluid and expanding the Teflon ring (09630-24014). Install new Teflon rings from the control valve assembly using SST 09631-20081 after expanding them, coating them with lubricant, and placement. Drive out the 2 union seats using a screw extractor followed by installation of fresh mounting units. Reassemble the rack and pinion by using power steering fluid and molybdenum disulfide lithium base grease on the parts before installing it with SST 09631-16020 while additional coating the rack with power steering fluid. Fitting of the oil seal must follow a precise direction before using SST 09612-22011 to install the cylinder end stopper. The inspection requires SST 09631-12071 and a vacuum pressure of 53 kPa (400 mmHg, 15.75 inch Hg). Place the control valve assembly along with the upper bearing and upper oil seal while ensuring the oil seal points toward its proper direction. Prepare and install SST 09616-00011 self-locking nut to 12 Nm (125 kgf-cm, 9 ft. lbs.) torque level while using SST 09616-00011 stake to prevent its movement. A sealant application on the rack housing cap threads should be followed by installation then torquing at 69 Nm (700 kgf-cm, 51 ft. lbs.). Apply a sealant to the rack guide spring cap threads before installing all components including the rack guide and its related parts. Totally adjust rack preload by setting up the rack ends temporarily then applying torque to the rack guide spring cap reaching 25 Nm (250 kgf-cm, 18 ft-lbs) and rotating the cap back 12° along with preload adjustment until values match specifications. After installation of the rack guide spring cap lock nut with sealant users must torque it to 32 Nm using SST 09922-10011 while rechecking the total preload. The procedure ends with clamp and boot installation to the rack before finishing with tie rod end assembly followed by SST 09023-38200 usage to install turn pressure tubes torqued to 27 Nm (270 kgf-cm, 20 ft. lbs.).