OEM 2004 Toyota MR2 Spyder Rack And Pinion

2004 Toyota MR2 Spyder Parts Questions & Experts Answers

• Q: How to service and repair the Rack And Pinion on 2004 Toyota MR2 Spyder?

  A: The beginning of rack and pinion service and repair starts with removing the 2 turn pressure tubes through the use of Special Service Tool: 09023-38200 and extracting the 4 O-rings from them. Install the Rack And Pinion assembly into a vise by using Special Service Tool: 09612-00012. Commence by applying marks on the tie rod ends along with rack ends before unstowing the lock nuts for removing LH and RH tie rod ends. You should use a screwdriver to loosen the clamps before removing clips and clamps and rack boots without damaging the boots. Use Special Service Tool: 09922-10010 on the LH rack end to remove it followed by the RH rack end after application of the tool on both ends. Use Special Service Tool: 09922-10010 to remove its lock nut and proceed to take out the rack guide spring cap and rack guide spring and rack guide subassembly using a 19 mm hexagon wrench. Use Special Service Tool: 09616-00011 to detach the rack housing cap and the self-locking nut. Mark bolt positions to remove rack and pinion control valve housing and its assembly before extracting both assembly and oil seal from the components. To remove the snap ring you need to use needle nose pliers so you can pull out the cylinder end stopper. Rephrase the rack and pinion by pressing it against the bushing through Special Service Tool: 09950-70010 (09951-07200) to remove its O-ring from the bushing. Check the rack and pinion's spots for wear as well as damage and verify that maximum runout measures less than 0.1 mm (0.004 inch). Insert the new rack housing oil seal through Special Service Tool: 09950-60010 (09951-00210, 09951-00240, 09952-06010) after applying power steering fluid to the lip of the seal before installing it into the rack housing. The control valve housing requires Special Service Tool: 09950-60010 (09951-00260) to remove its bearing and oil seal. Therefore install new components with correct orientation. Replace the No.1 and No.2 bearings of the rack housing using the correct Special Service Tools while applying grease. Use Special Service Tool: 09612-24814 (09613-22011) to remove the oil seal from the rack and pinion bushing then install a new one according to proper orientation. First uninstall the rack and pinion's teflon ring and O-ring then install a new O-ring before carefully installing the new teflon ring while expanding it. The control valve assembly requires removal of its four teflon rings together with new ring installation using Special Service Tool: 09631-20081. The process of reassembly requires power steering fluid or molybdenum disulfide lithium base grease coatings on the parts before installing the rack and pinion using Special Service Tool: 09631-10041 while attending to the bushing and cylinder end stopper installation. Use Special Service Tool: 09631-12071 (09633-00010) for an air tightness test while installing the control valve assembly without harming the teflon rings. To install the control valve assembly oil seal first use Special Service Tool: 09612-22011 before installing the control valve housing and gasket with matching mark alignment and torque bolt bolts to 21 Nm (210 kgf-cm, 15 ft. lbs.). The technicians must tighten the self-locking nut to 24.5 Nm (250 kgf-cm, 18 ft. lbs.) then use sealant on the rack housing cap before staking and tightening it to 59 Nm (600 kgf-cm, 43 ft. lbs.). The rack guide sub-assembly requires final assembly with its components and spring adjustment to 0.8 - 1.3 Nm (8 - 13 kgf-cm, 6.9 - 11.3 inch lbs.) before installing the rack guide spring cap lock nut to 28 Nm (290 kgf-cm, 21 ft. lbs.). The last phase includes installing the rack ends in the proper torque sequence of 62 Nm (630 kgf-cm, 46 ft. lbs.) then applying new O-rings to the turn pressure tubes before completing installation by torquing the tubes to 10 Nm (100 kgf-cm, 7 ft. lbs.).