OEM 2003 Toyota MR2 Spyder Rack And Pinion

2003 Toyota MR2 Spyder Rack And Pinion Parts Q&A

• Q: How to service and repair the Rack And Pinion on 2003 Toyota MR2 Spyder?

  A: Start the rack and pinion service and repair procedure by utilizing Special Service Tool: 09023-38200 to remove both turn pressure tubes with their 4 O-rings. Secure the Rack And Pinion assembly within Special Service Tool: 09612-00012 when set up in a vise. Follow the steps below to remove the right hand and left hand tie rod ends while marking their positions first and then loosening their lock nuts. Use a screwdriver to gently unfasten the clamps for removing clips and rack boots and clamps which should not result in damage to the boots. Apply Special Service Tool 09922-10010 to hold the LH rack end before removing the RH rack end with this tool and then perform the same procedure for the LH rack end. Remove the rack guide spring cap lock nut using Special Service Tool: 09922-10010 and then complete the removal sequence of rack guide spring cap followed by rack guide spring and rack guide subassembly using a 19 mm hexagon wrench. Extract the rack housing cap and self-locking nut by applying Special Service Tool: 09616-00011. In the next step remove the control valve housing together with its control valve assembly while making matchmarks for later installation. Also remove the gasket. Wipe down the control valve shaft with vinyl tape while pressing out the control valve assembly without harming the oil seal lip. After removing the oil seal from the control valve assembly, pinpoint pliers can be used to extract the snap ring and extract the cylinder end stopper. Special Service Tool: 09950-70010 (09951-07200) can be used to press the rack and pinion with its bushing before removing the O-ring from the bushing. During the inspection check the rack and pinion for a maximum runout of 0.1 mm (0.004 inch) while also inspecting the teeth wear and damage along with any visible damage. Press the new oil seal of the rack housing into place using Special Service Tool: 09950-60010 (09951-00210, 09951-00240, 09952-06010) after treating the lip with power steering fluid. To replace the oil seal and bearing of the control valve housing use Special Service Tool: 09950-60010 (09951-00260) followed by installation of the new oil seal with Special Service Tool: 09950-60910 (09951-00180, 09951-00330, 09952-06010). Use appropriate special service tools to replace the No.1 and No.2 rack housing bearings while applying grease. Insert the replacement oil seal into the rack and pinion bushing by using Special Service Tool: 09612-24814 (09613-22011). The rack and pinion requires new teflon rings with the replacement of its teflon ring and O-ring but caution should be taken not to damage the teflon ring groove. Coat replaced parts with power steering fluid and molybdenum disulfide lithium base grease before installing the rack and pinion with Special Service Tool: 09631-10041 while setting bushing direction correctly. Perform an air tightness test through Special Service Tool: 09631-12071 (09633-00010) but be cautious to not harm the teflon rings while installing the control valve assembly. After using Special Service Tool: 09612-22011 to install the control valve assembly oil seal, mount the control valve housing with new gasket using matchmarks and achieve bolt torque of 21 Nm (210 kgf-cm, 15 ft. lbs.). The self-locking nut should get torqued to 24.5 Nm (250 kgf-cm, 18 ft. lbs.) while the rack housing cap requires installation with sealant followed by a torquing process to 59 Nm (600 kgf-cm, 43 ft. lbs.). The rack guide sub-assembly along with rack guide spring and rack guide spring cap requires installation while adjusting total preload to 0.8 - 1.3 Nm (8 - 13 kgf-cm, 6.9 - 11.3 inch lbs.). The rack guide spring cap lock nut requires sealant before torque application to 28 Nm (290 kgf-cm, 21 ft. lbs.). Following this step, install the RH and LH rack ends with a 62 Nm (630 kgf-cm, 46 ft. lbs.) torque specification. Complete the installation of the rack boots and clamps first by maintaining a clear opening at the rack end hole and torque the pressure tubes to 10 Nm (100 kgf-cm, 7 ft. lbs.) after lubricating fresh power steering fluid on the new O-rings.