OEM 2002 Toyota Tacoma Rack And Pinion

2002 Toyota Tacoma Rack And Pinion Parts Q&A

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

  A: Before starting the repair process of the rack and pinion unit begin by unassembling the components while avoiding excessive vise tension. I will use Special Service Tool: 09023-38200 to remove the 2 turn pressure tubes before extracting the 4 O-rings. Fasten the Rack And Pinion assembly into a vise using Special Service Tool: 09612-00012. Begin by marking both tie rod ends and rack ends before loosening their associated lock nuts and tie rod ends on each side. The clamps must be loosened with a screwdriver to remove both RH and LH clips along with rack boots and clamps while protecting the rack boots from damage. Use a screwdriver and hammer to unstake claw washers before using a spanner to stabilize the rack and pinion while removing its ends with Special Service Tool: 09922-10010 and then removing the claw washers. Attach marks to the rack ends of RH and LH before removing the bolt and rack housing No.2 bracket and grommet. The repair process begins with removal of the rack guide spring cap lock nut through Special Service Tool: 09922-10010. Subsequently, the rack guide spring cap, rack guide spring, rack guide and rack guide seat are extracted using Special Service Tool: 09631-10021. The control valve shaft needs to be stabilized using Special Service Tool: 09616-00011 so its movement can be stopped while you remove the rack housing cap followed by the self-locking nut. Begin by marking both the housing and rack housing then remove the two bolts. Proceed to take off the dust cover and the control valve housing including the control valve assembly. Carefully extract the control valve housing and detach the seal gasket during the operation. Whip a piece of vinyl tape around the serrated valve shaft because using the tape will push out the control valve assembly with the oil seal while placing a shop rag between the blocks and valve housing to prevent the assembly from falling. The control valve assembly needs its oil seal removed next while using Special Service Tool: 09631-10021 to turn the cylinder end stopper clockwise until the wire end is exposed before turning it counterclockwise to remove both the wire and the cylinder end stopper. With a 19 mm socket wrench along an extension bar remove the rack and pinion's bushing through pressing and extract the bushing alongside the O-ring while preventing any rack drops. Special Service Tools 09950-60010 (09951-00280) and 09950-70010 (09951-07360) should be used to push out the oil seal through this process. A dial indicator should be used to measure rack and pinion runout and wear patterns while ensuring maximum defects do not exceed 0.3 mm (0.0118 inch). Follow this procedure to use Special Service Tool: 09950-60010 (09951-00260), 09950-70010 (09951-07150) to press in the new oil seal after coating it with power steering fluid. Apply corresponding tools to install new bearings after you remove old ones with a hammer and brass bar. Special Service Tools: 09527-20011, 09612-24014 (09613-22011) must be used to uninstall the oil seal after which the new seal lip receives power steering fluid treatment prior to installation with Special Service Tool: 09950-60010 (09951-00240, 09951-00400, 09952-06010). When replacing the teflon ring and O-ring of the rack and pinion keep the teflon ring groove intact while applying power steering fluid to the new O-ring before installation. Special Service Tool: 09631-20081 will guide the controlled installation of teflon rings in the control valve assembly as long as grooves remain undamaged. The 2 union seats in the control valve housing should be removed with a screw extractor and new seats should be gently tapped into place using a plastic hammer. To rebuild this area apply power steering fluid together with molybdenum disulfide lithium base grease on indicated components before installing the oil seal in the correct orientation and using Special Service Tool: 09631-20102 to assemble the rack and pinion. Begin with an application of power steering fluid to a new O-ring before setting the bushing in place according to direction specifications. Fit the cylinder end stopper while lining up its wire installation hole and apply clockwise torque of 450 plus or minus 50 degrees. Apply a vacuum of 53 kPa (400 mmHg, 15.75 inch Hg) through Special Service Tool: 09631-12071 for 30 seconds to conduct an air tightness test. The control valve assembly installation must avoid damaging teflon rings and oil seal lip while Special Service Tool: 09612-22011 press fits the oil seal. Fasten the control valve housing to its place using the new gasket while keeping matchmarks aligned and tighten its bolts to 18 Nm (185 kgf-cm, 13 ft. lbs.). Use Special Service Tool: 09616-00011 to install the self-locking nut and torque it to 25 Nm (250 kgf-cm, 18 ft. lbs.). Put on the dust cover and rack housing cap while applying sealant to those threads, then torque to 59 Nm (600 kgf-cm, 43 ft. lbs.). Secure the rack housing cap before placing the rack guide seat followed by rack guide, rack guide spring and rack guide spring cap. Use sealant on the cap threads during installation. The total preload adjustment process requires installing RH and LH rack ends with temporary torque of 25 Nm (250 kgf-cm, 18 ft. lbs.) on the rack guide spring cap and setting the cap to 12 degrees followed by rotating the control valve shaft. Washers should be adjusted by loosening the rack guide spring cap until the spring stops functioning before tightening it once the preload reaches the optimal range of 0.9 to 1.5 Nm. The rack guide spring cap lock nut requires sealant before torquing it to 50 Nm (513 kgf-cm, 37 ft. lbs.) and rechecking the total preload. The rack housing No.2 bracket and grommet installation requires matching up the marks before torquing the bolt to 61 Nm (620 kgf-cm, 45 ft. lbs.). Next, position the RH and LH claw washers with the rack ends into the rack and pinion grooves while torquing the ends to 60 Nm (615 kgf-cm, 45 ft. lbs.). Use the 2 turn pressure tubes with power steering fluid coating on new O-rings before torquing them to 12 Nm (122 kgf-cm, 9 ft. lbs.).