OEM 2004 Toyota Prius Rack And Pinion

2004 Toyota Prius Parts Questions & Experts Answers

• Q: How to overhaul the Rack And Pinion assembly on 2004 Toyota Prius?

  A: The first step to overhaul the rack and pinion requires proper front wheel alignment towards straight direction. You should remove the column hole silencing sheet from the cover before you separate the sliding yoke sub-assembly by fixing the steering wheel with a seat belt for stability and marking the assembly components. Loosen bolt A first and remove bolt B afterwards. The first step includes detaching the steering column hole cover sub-assembly No.1 while removing clip A gently yet avoiding any damage to clip B. Afterward, extract the front wheels followed by eliminating the left and right tie rod ends and the front stabilizer link assembly and both front stabilizer brackets No.1. To extract the steering intermediate shaft first move up the column hole cover No.1 to release the intermediate shaft. Then perform markings on both components and break the retaining bolt free. After four bolt removal from the rack and pinion assembly keep away from contact with the stabilizer bar. Fasten the rack and pinion assembly to a vise through the use of Special Service Tool: 09612-00012 which requires protection tape covering it. First detach both sub-assemblies of left and right tie rod ends then mark them along with their rack ends before proceeding to remove both sub-assemblies again. The left tie rod end sub-assembly inspection begins by mounting it in a vise and tightening the castle nut then rotating the ball joint while testing turning torque before replacement when out of specification. The inspection procedure should be duplicated for the right tie rod end sub-assembly. Proceed with boot clip and clamp removal from the steering rack while protecting boot integrity and detach both boots. Secure both rack end sub-assemblies using two Special Service Tool: 09922-10010 while maintaining correct directional usage. The inspection requires Special Service Tool: 09616-00011 to check total preload and the rack and pinion assembly must be replaced if it exceeds specifications. Mount the rack end sub-assemblies while filling ball joints with grease and applying torque of 60 Nm (612 kgf-cm, 44 ft. lbs.) using a torque wrench in the correct manner. Both steering rack boots receive silicon grease before their installation and the application of clamps and clips concludes the process while double-checking an absence of boot twists. Check how rack and pinion assembly components move after turning the pinion shaft and inspecting the rack boot functions. The left and right tie rod sub-assemblies should go under installation while the lock nut needs to be tightened temporarily. Install the rack and pinion assembly from the left side while avoiding contact with the stabilizer bar then bolt it to the crossmember with four fasteners at 58 Nm (591 kgf-cm, 43 ft. lbs.). The steering intermediate shaft should be installed with the bolt tightened at 35 Nm (360 kgf-cm, 26 ft. lbs.) while ensuring that hole cover No.1 remains unharmed. Begin installation by placing both front stabilizer brackets followed by installing stabilizer link and final assembly of tie rod end sub-assemblies. Secure the front wheels at 103 Nm (1,050 kgf-cm, 76 ft. lbs.) after which install sub-assembly No.1 of the column hole cover. Proper fitting should be verified. The last step involves aligning the matchmarks to install the sliding yoke sub-assembly while tightening both bolts to 35 Nm (360 kgf-cm, 26 ft. lbs.). Then, reinstall the column hole cover silencer sheet followed by ensuring front wheel straightness. Check and adjust front wheel alignment while performing steering angle sensor zero point calibration.