OEM 2004 Toyota Echo Rack And Pinion

2004 Toyota Echo Parts Questions & Experts Answers

• Q: How to disassemble the Rack And Pinion on 2004 Toyota Echo?

  A: The vise should not be tightened excessively when disassembling the rack and pinion. Remove the pressure tubes through SST 09023-38200 while extracting the four O-rings from their mounting points. The Rack And Pinion assembly needs to be fixed inside a vise using SST 09612-00012. The first step is to mark both the tie rod end and rack end before loosening the lock nuts on the tie rod ends on both sides. Use a screwdriver to remove the RH and LH clips and clamps from the rack boots by loosening their clamps while safeguarding the boot material and marking these components. Beginning with SST 09922-10010 grip the RH rack end and then remove the LH rack end followed by holding the rack and pinion LH side to remove the RH rack end while SST 09922-10010 must be used according to direction. SST 09922-10010 allows the removal of the rack guide spring cap lock nut which provides access for a hexagon wrench (19 mm) to separate the rack guide spring cap from the rack guide spring after removing the rack guide spring spacer and the rack guide sub-assembly. The control valve assembly removal starts with the step of marking both the control valve housing and rack housing followed by unscrewing two bolts to pull out the assembly and finally removing the gasket. Use needle nose pliers to remove the snap ring which enables you to take out the cylinder end stopper. Press the rack and pinion out of position using SST 09950-70010 (09951-07200) with the bushing in place while removing the O-ring that is present on the bushing. Squeeze out the oil seal from the rack housing using SST 09950-60010 (09951-00240) and SST 09950-70010 (09951-07360) while protecting the rack housing integrity. A dial indicator should be used to check runout on the rack and pinion while measuring maximum 0.1 mm (0.004 inch) and inspecting the back surface for wear. The needle roller bearing needs inspection for damage before the internal space receives an application of molybdenum disulfide lithium base grease. Follow these steps for oil seal replacement by removing it from the bushing with SST 09612-24014 (09613-22011) but preserve the bushing integrity and use new power steering fluid to lubricate a new seal before installation with SST 09950-60010 (09951-00210, 09951-00340, 09952-06010) and 09950-70010 (09951-07100) following directional specifications. The correct procedure for part replacement includes extracting the teflon ring and O-ring from the rack and pinion followed by applying power steering fluid to a new O-ring while expanding and applying fluid to a new teflon ring before installing it to the rack and pinion. When assembling the system coat parts that need power steering fluid or molybdenum disulfide lithium base grease and install the oil seal before pressing it into the rack housing with SST 09950-60010 (09951-00210, 09951-00370, 09952-06010), 09950-70010 (09951-07360) while placing it in the proper orientation. Proceed by installing SST 09631-10041 to the rack then moisten it with power steering fluid before slotting in the rack and pinion into the rack housing while removing the SST piece. First apply power steering fluid to a new O-ring before installing it to the bushing. The rack and pinion end must receive vinyl tape to protect the oil seal lip before placing the bushing within the rack housing while maintaining the correct direction. Use needle nose pliers to push the stopper of the cylinder then install the snap ring. To conduct the air tightness test using SST 09631-12071 (09633-00010) on the rack housing, apply 53 kPa (400 mm Hg, 15.75 inch Hg) of vacuum for about 30 seconds and check for any vacuum change. Install the new control valve assembly gasket then align matchmarks before pushing in the assembly with proper torque of 21 Nm (220 kgf-cm, 15 ft. lbs.) applied to each of the two bolts. Fit the rack guide sub-assembly together with the rack guide spring spacer and rack guide spring and rack guide spring cap but place the spacer in its correct orientation and use sealant on 2 or 3 threads of the rack guide spring cap. Adjust the total preload after installing temporary RH and LH rack ends while torquing the rack guide spring cap to 25 Nm (250 kgf-cm, 18 ft. lbs.) until it reaches a 12-degree angle and uses SST 09616-00011 to turn the control valve shaft to minimize spring function then retightens until the preload stays within 1.2 - 1.4 Nm (12 - 14 kgf-cm, 10.4 - 12.2 inch lbs.). Fasten the rack guide spring cap lock nut through application of sealant then torque it to 28 Nm (290 kgf-cm, 21 ft. lbs.) using SST 09922-10010 and double-check total preload. As the last step install the RH and LH rack ends by tightening them to 62 Nm (630 kgf-cm, 46 ft. lbs.) with SST 09922-10010 before installing the RH and LH rack boots along with the clamps and clips by checking that the rack and pinion end hole does not have grease buildup, fasten the clamps with SST 09521-24010, then repeat the process for the other side before installing the 2 turn pressure tubes with new O-rings coated in power steering fluid using SST 09023-38200 and torquing them to 11 Nm.