OEM 2004 Toyota Echo Rack And Pinion

2004 Toyota Echo Rack And Pinion Parts Q&A

• Q: How to disassemble and reassemble the manual Rack And Pinion assembly on 2004 Toyota Echo?

  A: The manual rack and pinion assembly must be fixed in a vise through the use of Special Service Tool: 09612-00012 before proceeding with tie rod end removal. Place matching marks on each piece to loosen the lock nuts and extract both the RH and LH components. Use pliers to detach the RH and LH clips along with clamps from the rack and pinion assembly but protect the boots and record their identification. Use Special Service Tool: 09922-10010 to remove the RH and LH rack ends while maintaining a stable grip on the rack and pinion and make corresponding markings of the components. Remove the rack guide spring cap lock nut using Special Service Tool: 09922-10010 and proceed to take off the rack guide spring cap followed by the rack guide spring spacer and conical spring washer then the rack guide spring and rack guide sub-assembly. The installation of vinyl tape on a screwdriver allows technicians to remove the oil seal and spacer and steering pinion from the rack housing without damaging its components; snap ring pliers help separate the spacer and snap ring while being cautious of their serrations. Avoid rotating the rack and pinion when taking it out and perform the removal process from the steering pinion housing side. A dial indicator helps to inspect the rack and pinion for runout while checking teeth wear and damage with the condition that maximum runout remains under 0.15 mm (0.0059 inch). Apply molybdenum disulfide lithium base grease to the specified components before putting in the rack and pinion from the pinion end without rack rotation while orienting the notched section of the rack toward the pinion. Use snap ring pliers to install the snap ring while pushing the steering pinion into place. Then add the spacer and grease-coated new oil seal by using Special Service Tool: 09517-12010 with a hammer for installation. Next install the rack guide sub-assembly along with the rack guide spring, conical spring washer, rack guide spring spacer, along with the rack guide spring cap which requires sealant on its threaded section. The rack guide spring cap requires temporary installation so operators can adjust total preload by mounting RH and LH rack ends and torque to 6.9 Nm (70 kgf-cm, 61 inch lbs.) then use Servicing Tool: 09612-24014 (09616-10010) to turn the pinion shaft. Tighten the rack guide spring cap beginning from loose condition until the preload falls between 0.6 - 1.5 Nm (6 - 15 kgf-cm, 5.2 - 13.0 inch lbs.). Position the rack guide spring cap lock nut with sealant applied to the threads in place while using Special Service Tool: 09922-10010 to tighten it to 36 Nm (365 kgf-cm, 26 ft. lbs.), then double-check the total preload. Use Special Service Tool: 09922-10010 to install RH and LH rack ends at 62 Nm (630 kgf-cm, 46 ft. lbs.) before putting on rack boots with their clamps and clips while avoiding boot damage and twisting. Lastly, install RH and LH tie rod ends and lock nuts applying torque to 47 Nm (480 kgf-cm, 35 ft. lbs.) by matching notches.