OEM 2003 Toyota Echo Rack And Pinion

2003 Toyota Echo Rack And Pinion Parts Q&A

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

  A: The rack and pinion repair process starts with removing the 2 turn pressure tubes through the use of Special Service Tool: 09023-38200 to extract the 4 O-rings. The Rack And Pinion assembly requires securement into a vise through the use of Special Service Tool: 09612-00012. Before removing the tie rod ends begin by marking them along with the rack ends and releasing their lock nuts. Use a screwdriver to release the clamps before taking off the clips and clamps as well as rack boots without scratching the boot surface and mark the RH and LH rack boots. The RH rack end must stay steady while using Special Service Tool: 09922-10010 to remove the LH rack end followed by the RH rack end removal procedure. The necessary installation steps require removal of the rack guide spring cap lock nut through using Special Service Tool: 09922-10010 followed by removal of rack guide spring cap then rack guide spring and rack guide spring spacer and rack guide sub-assembly with use of a 19 mm hexagon wrench. First mark the housing of the control valve assembly and then remove two bolts to finally extract the assembly with its gasket. Use needle nose pliers to extract the cylinder end stopper's snap ring before pressing out the rack and pinion with the bushing by using Special Service Tool: 09950-70010 (09951-07200). After that remove the O-ring from the bushing. Special Service Tool: 09950-60010 (09951-00240) and 09950-70010 (09951-07360) should be used to press out the oil seal without damaging the rack housing. The rack and pinion needs thorough examination for its runout along with assessing teeth wear and damage. Maximum runout should be 0.1 mm (0.004 inch) and the needle roller bearing requires inspection for damage with replacement of the rack housing if needed. For oil seal replacement use Special Service Tool: 09612-24014 (09613-22011) to press in a new oil seal whose lip should receive power steering fluid application prior to installation with Special Service Tools: 09950-60010 (09951-00210, 09951-00340, 09952-06010) and 09950-70010 (09951-07100). To install new teflon ring and O-ring start by removing them with a screwdriver before coating a new O-ring with power steering fluid and expanding and installing the new teflon ring correctly. Reassemble while applying power steering fluid or molybdenum disulfide lithium base grease to indicated parts and place the oil seal correctly before rack and pinion installation with Special Service Tool: 09631-10041. Before installing the bushing into the rack housing examine its correct direction and place a new O-ring that received power steering fluid coating onto the bushing then mount the bushing into position. The snap ring needs to be installed following cylinder end stopper push. Test the air tightness using Special Service Tool: 09631-12071 (09633-00010) which applies 53 kPa (400 mm Hg, 15.75 inch Hg) vacuum pressure for 30 seconds to check if the vacuum level changes. Place a new control valve assembly gasket before installing the assembly and setting its matchmarks in proper position. Secure the assembly by torqueing the 2 bolts to 21 Nm while using a torque wrench. Form a seal by applying sealant on the threads of the rack guide spring cap before installing the rack guide spring spacer, rack guide spring, rack guide sub-assembly followed by the rack guide spring cap. Determine the overall total preload by installing the RH and LH rack ends temporarily while tightening the rack guide spring cap to 25 Nm (250 kgf-cm, 18 ft. lbs.) before rotating it to 12 degrees. Pass the control valve shaft through Special Service Tool: 09616-00011 to loosen the rack guide spring cap down to a non-functioning state and apply a preload of 1.2 - 1.4 Nm (12 - 14 kgf-cm, 10.4 - 12.2 inch lbs.). Fitting a rack guide spring cap lock nut with sealant requires the use of Special Service Tool: 09922-10010 to achieve a torque of 28 Nm (290 kgf-cm, 21 ft. lbs.) before rechecking the total preload. Finish the installation and maintenance by torquing RH and LH rack ends to 62 Nm (630 kgf-cm, 46 ft. lbs.), installing RH and LH rack elements with their respective clamps and clips, then clearing the rack and pinion end opening before adding two pressure tubes with new O-rings applied in power steering fluid, and torquing them to 11 Nm (110 kgf-cm, 8 ft. lbs.).