OEM 2003 Toyota Avalon Rack And Pinion

2003 Toyota Avalon Parts Questions & Experts Answers

• Q: How to service and repair the Rack And Pinion on 2003 Toyota Avalon?

  A: Service and repair of the rack and pinion starts with vise-secured Rack And Pinion assembly using special tool: 09612-00012 before using special tool: 09023-38200 to remove the 2 turn pressure tubes followed by removal of the 4 O-rings. Make all necessary marks on the tie rod ends and rack ends prior to untightening the lock nuts to remove the tie rod ends. Use a screwdriver to loosen the clamps in order to remove RH and LH clips, rack boots and clamps without causing damage to the rack boot. Use a screwdriver in combination with a hammer to unstake the claw washers while using a 24 mm spanner to stabilize the rack and pinion before removing the rack ends through Special Service Tool: 09922-10010 according to the specified direction. Specific Service Tools 09922-10010 and 09631-10021 help in removing the rack guide spring cap from its lock nut and proceeding to extract the guide spring and rack guide sub-assembly. First remove the rack housing cap along with the self-locking nut through the use of Special Service Tool: 09616-00011 before taking off the dust seal and control valve housing together with their control valve assembly while noting matchmarks for future alignment. Apply vinyl tape onto the control valve shaft to protect the seal lip and push out the control valve assembly with oil seal while inserting a shop rag between blocks and valve housing. Remove the control valve assembly oil seal before proceeding to separate the rack housing No. 2 bracket and grommet and finish by extracting the cylinder end stopper using Special Service Tool: 09631-10021. Press out the oil seal from the rack and pinion with the required Special Service Tools which are 09950-60010 (09951-00290) and 09950-70010 (09951-07360). Use Special Service Tool: 09950-60010 (09951-00250), 09950-70010 (09951-07200) to inspect the rack and pinion for runout as well as wear before replacing any necessary oil seal and bearing parts while applying power steering fluid to new oil seal lips. Apply power steering fluid to new O-rings and Teflon rings before installing them into the system. Bear in mind that bearing replacements might be necessary. Whichever method you choose apply between power steering fluid and molybdenum disulfide lithium base grease onto the parts then place the oil seal within the rack and pinion through use of Special Service Tool: 09950-60010 (09951-00240, 09951-00430, 09952-06010) while maintaining the oil seal lip free of damage. Mount the bushing and cylinder end stopper before testing for air tightness with Special Service Tool: 09631-12071 while placing the rack housing No. 2 bracket and grommet. The control valve assembly installation requires Teflon ring protection while using Special Service Tool: 09612-22011 to press in the oil seal. The installation of control valve housing requires combining it with the control valve assembly while torquing bolts to 18 Nm and tightening the self-locking nut to 25 Nm. Terminates the installation process by fitting the dust seal followed by the rack housing cap with sealant and the rack guide sub-assembly and adjusts the total preload using Special Service Tool: 09631-10021 before locking and torquing the rack guide spring cap to 50 Nm. Test the total preload and proceed to install the RH and LH claw washers and rack ends before torquing up to 60 Nm before finishing up with rack boot and clamp installation which should include clip installation and should maintain a clear rack and pinion hole opening. The installation process requires new O-rings for the two turn pressure tubes before torquing them to 12 Nm.