OEM 2004 Toyota Highlander Rack And Pinion

2004 Toyota Highlander Parts Questions & Experts Answers

• Q: How to Overhaul a Rack and Pinion Steering Gear on 2004 Toyota Highlander?

  A: First.Wrap a new rack bush oil seal lip with power steering fluid then install it to the rack bush with Special Service Tool: 09950-60010 (09951-00400), 09950-70010 (09951-07100) and a press while ensuring proper rack bush oil seal orientation. The next step requires power steering fluid coating on a new O-ring before installation to the rack bush. Then apply power steering fluid to the rack bush oil seal lip and position it into the rack housing after wrapping the rack and pinion end with vinyl tape to protect the oil seal. Insert the installation hole of the wire into the slot of the rack housing then install a new wire before turning the cylinder end stopper counter-clockwise between 450 degrees plus or minus 50 degrees by using a screwdriver. An air tightness test requires use of Special Service Tool: 09631-12071 (09633-00010) which should be installed onto the rack housing while the vacuum pressure stays at 53 kPa (398 mmHg, 15.65 in.Hg) for about 30 seconds and a pressure change indicator is required to pass the test. Before sealing installation use Special Service Tool: 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320) and 09950-60006 (09952-01011) and a suitable press to place the power steering control valve upper oil seal. Apply power steering fluid to the control valve upper bearing grease and new oil seal lip which should be oriented correctly. The control valve upper bearing installation requires Special Service Tool: 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340) and a press to accomplish proper fitting. Place four new valve spacers into position then apply power steering fluid on each spacer before installing them to the control valve. Following this, use Special Service Tool: 09631-20081 with caution to insert its tapered end over the valve spacers until they fit onto the control valve. Next, apply power steering fluid to the oil seal lip before installing the control valve into the valve housing while being careful to protect both the valve spacer and oil seal lip. Use Special Service Tool: 09612-22011 together with a press to install a new power steering fluid-coated oil seal lip with proper orientation before applying grease to the needle roller bearing and serrated part of the control valve. Next, apply a new gasket to the valve housing and secure the control valve housing to the rack housing using 2 bolts torqued at 21 Nm (214 kgf-cm, 15 ft-lbf). After torquing to 25 Nm (250 kgf-cm, 18 ft-lbf) a new lock nut, use Special Service Tool: 09616-00011 to secure the control valve while applying sealant to 2 or 3 threads of the rack housing cap (Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent) for installation with a socket wrench (27 mm) that requires 59 Nm (597 kgf-cm, 43 ft-lbf) torque and subsequent staking with a punch and hammer. Compress the spring with grease while applying sealant to 2 or 3 threads of the rack guide spring cap. Then mount the rack guide followed by the compression spring before temporarily placing the rack guide spring cap. The procedure requires a temporary installation of the RH and LH rack ends sub-assy to safeguard the oil seals before torquing the rack guide spring cap to 25 Nm (250 kgf-cm, 18 ft-lbf) using Special Service Tool: 09631-10021 and loosening the cap to regulate control valve movement right and left 1 or 2 times and further loosening until the compression spring stops functioning. After the rack guide spring cap reaches preload specifications between 1.2 to 1.5 Nm (12.2 to 15.3 kgf-cm, 10.6 to 13.3 in.-lbf), apply sealant to 2 to 3 threads of the lock nut before installing it temporarily and torquing it to 51 Nm (515 kgf-cm, 38 ft-lbf) while using Special Service Tool: 09616-00011 and 09922-10010 to support the rack guide spring cap. The service procedure includes the following steps: checking the total preload, removing the RH and LH rack ends sub-assy and applying MP grease around the control valve shaft followed by vinyl tape wrapping around the spline of the control valve before installing the dust cover to the control valve housing. Temporarily attach both rack ends sub-assy to the rack and pinion groove but keep the claws in the proper position with Special Service Tool: 09922-10010. Torque the rack end sub-assy to 60 Nm (616 kgf-cm, 45 ft-lbf) by avoiding contact with the rack and pinion. The technician must test the rack and pinion end sub-assy for blocked holes and apply Special Service Tool: 09521-24010 to attach rack and pinion boots together with clamps before installing the auto-rocker assemble with a final lock nut torque rating of 74 Nm (750 kgf-cm, 54 ft-lbf). Power steering fluid coats two new O-rings before their installation to the left turn pressure tube, after using Special Service Tool: 09023-38200 to attach the tube to the steering link assembly, torque to 11 Nm (116 kgf-cm, 8 ft-lbf) and repeat for the right turn pressure tube. First connect the pressure feed tube assy through Special Service Tool: 09023-12700 and torque it to 22 Nm (230 kgf-cm, 16 ft-lbf). Next install the pressure feed tube assy clamp with its bolt torqued to 9.8 Nm (100 kgf-cm, 87 in.-lbf). The return tube assembly must connect to the steering link assembly through Special Service Tool: 09023-12700 and should be torqued at 22 Nm (230 kgf-cm, 16 ft-lbf) before installing the pressure feed tube clamp with its nut tightened to 9.8 Nm (100 kgf-cm, 87 in.-lbf). Torque the front stabilizer bracket bolts to 16 Nm and the front stabilizer link bolts to 35 Nm. To complete this procedure tighten the front wheels to 103 Nm (1,050 kgf-cm, 76 ft-lbf) and perform bleeding on the power steering fluid before inspecting the vehicle for leaks and checking front wheel alignment and calibration of steering angle sensors as well as steering wheel center point evaluation.