OEM 2004 Scion xB Rack And Pinion

2004 Scion xB Parts Questions & Experts Answers

• Q: How to Overhaul a Power Steering Rack and Pinion Assembly on 2004 Scion xB?

  A: Begin the power steering link assembly overhaul by installing Special Service Tool: 09631-10041 to the rack and pinion followed by burr removal from the rack and pinion teeth end if needed then applying power steering fluid to the tool before mounting the rack and pinion into the rack housing and unmounting the tool. After using Special Service Tools 09950-60010 (09951-00210, 09951-00340, 09952-06010) and 09950-70010 (09951-07100) with a press you will install the rack bush oil seal to the rack bush. Correct oil seal installation requires power steering fluid on the new O-ring while vinyl tape should be wrapped around the rack and pinion end to protect the oil seal lip before installing the rack bush into the rack housing. Place the cylinder end stopper and install the hole snap ring by using needle nose pliers. The installation of Special Service Tool: 09631-12071 (09633-00010) to the rack housing requires a 53 kPa vacuum for thirty seconds to perform air tightness testing. Any leak in the oil seals needs repair before continuing. First apply grease to the needle roller bearing followed by installing a new gasket to the rack housing and correctly positioning the matchmarks before securing the control valve housing with its attached control valve onto the rack housing through 2 bolts which require a torque setting of 21 Nm (214 kgf-cm, 15 ft. lbs.). Install the rack guide followed by the correct placement of the rack guide spring spacer before adding the rack guide spring. Apply Part No. 08833-00080 THREE BOND 1344 LOCTITE 242 or equivalent sealant to 2 or 3 threads of the rack guide spring cap then install the cap temporarily. The procedure to modify total preload involves using Special Service Tool: 09616-00011 to turn the control valve as you loosen the rack guide spring cap until the spring ceases functioning. Then use a torque wrench and hexagon wrench (19mm) to tighten the cap to a preload within 1.2 to 1.5 Nm (12 to 15 kgf-cm, 10.6 to 13.3 inch lbs.). Apply sealant to 2 or 3 threads of the spring cap lock nut, then fasten it temporarily before using the hexagon wrench (19 mm) to torque the rack guide spring cap to 28 Nm (286 kgf-cm, 21 ft. lbs.) using Special Service Tool: 09922-10010. The torque application requires a torque wrench with a fulcrum length of 345 mm (13.58 inch). Top all sub-assemblies with Special Service Tool (09922-10010) while they are torqued to 60 Nm (614 kgf-cm; 44 ft. lbs.) keeping the tool oriented according to direction specifications. The end hole of rack and pinion must be cleared of debris then silicon grease must be added inside rack boot No.2 before placing it into rack housing groove. The same sequence of action should be followed when installing rack boot No.1. Use Special Service Tool: 09240-00020, 09521-24010 to tighten rack boot No.2 clamp until it reaches a 3.0 mm (0.118 inch) or less clearance. Repeat this procedure for rack boot No.1 clamp. Cut the rack boot clips using pliers while simultaneously screwing the lock nut and tie rod end sub-assy LH onto the rack end sub-assy until matchmarks line up before applying torque to 74 Nm (750 kgf-cm, 54 ft. lbs.). The same process follows for the tie rod end sub-assy RH. Two fresh O-rings need application of power steering fluid before you install them inside the right turn pressure tube. The Special Service Tool: 09023-38200 guides the tube installation process with 12 Nm (118 kgf-cm, 9 ft. lbs.) torque along a torque wrench parallel axis. Tighten the left turn pressure tube after following the same fitting procedure. Use grommet No.2 to secure the link but maintain correct position of the matchmarks before installing bracket No.2 with its inscribed mark oriented toward the vehicle front. Complete this step by tightening the link assy with 4 bolts and nuts at 74 Nm torque strength and verifying the nut stays fixed. Use the steering intermediate shaft by matching alignment marks to secure the bolt at 28 Nm (290 kgf-cm, 21 ft. lbs.). The power steering rack housing heat insulator requires installation with its bolt torqued to 18 Nm (178 kgf-cm, 13 ft. lbs.) and the additional bolt torqued to 35 Nm (360 kgf-cm, 26 ft. lbs.). Support the front suspension crossmember sub-assy with a transmission jack then insert it through the holes after using Special Service Tool: 09670-00010. Secure the assembly with 4 bolts by torquing Bolt A to 116 Nm (1,183 kgf-cm, 86 ft. lbs.) and Bolt B to 70 Nm (714 kgf-cm, 52 ft. lbs.) followed by adding an additional bolt with 2 nuts torqued to 72 Nm (734 kgf-cm, 53 ft. lbs.) then install 2 reinforcements with 4 bolts torqu The front suspension arm sub-assy lower gets installed to both sides while the pressure feed tube assy connects using Special Service Tool: 09023-12700 before torquing to 27 Nm (273 kgf-cm, 20 ft. lbs.). Then connect the return hose with a clip before installing the tube clamp to the crossmember sub-assy by torquing its bolts to 7.8 Nm (80 kgf-cm, 69 inch lbs.). Install the front wheels, torquing to 103 Nm (1,050 kgf-cm, 76 ft. lbs.), install the steering sliding yoke sub-assy by aligning matchmarks and tightening the bolt to 28 Nm (290 kgf-cm, 21 ft. lbs.), inspect the center front wheel, install the steering column hole cover sub-assy No.1, add power steering fluid, bleed the power steering fluid, check the fluid level in the reservoir, inspect for fluid leaks, install the hood sub-assy, adjust the hood sub-assy, inspect and adjust front wheel alignment, and finally install the engine under cover LH, engine under cover RH, cowl panel sub-assy, windshield wiper motor & link assy, cowl top ventilator louver LH, cowl top ventilator louver RH, hood to cowl top seal, front wiper arm LH, and front wiper arm RH.