OEM 2004 Toyota Solara Rack And Pinion

2004 Toyota Solara Rack And Pinion Parts Q&A

• Q: How to Overhaul Rack and Pinion Power Steering Gear Assembly on 2004 Toyota Solara?

  A: The rack & pinion power steering rack and pinion assembly overhaul starts with an air tightness test that requires special service tool: 09631-12071 (09633-00010) to be installed on the rack housing while applying a vacuum of 53 kPa (398 mm Hg, 15.65 inch Hg) for 30 seconds to confirm stable vacuum pressure. Any pressure change signals the need to inspect the oil seals. Install new oil seal with power steering fluid on its lip following directions with special service tool 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320) and press tool. Afterward install the control valve upper bearing using the same tool set. The technician must expand four new valve spacers and coat them with power steering fluid before installing them onto the control valve using a proper adjustment followed by fitting special service tool: 09631-20081 over the spacers. The control valve installation requires the same attention to valve spacers and oil seal lip while you insert the new spacers into the valve housing and lubricate the oil seal lip. Follow this by using 09612-22011 and a press to correctly orient and seat the oil seal. Secure the rack housing to the control valve housing via 2 bolts which should reach 20 Nm torque (204 kgf-cm, 15 ft. lbs) while the needle roller bearing of rack housing together with control valve serrated part receives grease application. Use special service tool: 09616-00011 to prevent control valve rotation while installing the lock nut which should be torqued to 25 Nm (250 kgf-cm, 18 ft. lbs.) before applying part no. 08833-00080, three bond 1344, loctite 242 or equivalent sealant to 2 or 3 threads of the rack housing cap. Finally install the cap using a 27 mm socket wrench and torque it to 59 Nm (597 kgf-cm, 43 ft. lbs.) and stake the cap and housing. Lubricate the rack guide contact surface and install both its components while also applying sealant to the rack guide spring cap threads before doing a provisional mounting. The RH and LH rack end sub-assemblies need temporary installation for adjusting total preload through torquing the rack guide spring cap to 25 Nm (250 kgf-cm, 18 ft. lbs.) with special service tool: 09631-10021, followed by loosening torques and rotating the control valve before eventual spring cap stress reduction when the compression spring no longer functions. First tighten the spring cap using a torque of 1.2 to 1.5 Nm (12.2 to 15.3 kgf-cm, 10.6 to 13.3 inch lbs.) then apply sealant to the spring cap lock nut threads before applying the lock nut which needs to be torqued to 51 Nm (520 kgf-cm, 38 ft. lbs.) using special service tool: 09616-00011 and 09922-10010 while following the specified direction using a torque wrench with a fulcrum length of 345 mm (13.58 Check the combined preload value again before removing both rack end sub-assemblies to apply MP grease on the control valve shaft then wrap it with vinyl tape followed by installing the dust cover. Use two new claw washers and attach the LH and RH steering rack end sub-assemblies to the steering rack grooves temporarily before securely torquing the rack ends to 60 Nm (615 kgf-cm, 45 ft. lbs.) with special service tool: 09922-10010 while taking care to prevent steering rack impact. Check for any hole blockages in the power steering rack followed by silicoapplication inside the small opening of rack boot No.2 before installing the rack boot into the groove of the rack housing. Repeat this process with rack boot No.1 Use special service tool: 09521-24010 to clamp the rack boot No.2 until it reaches a clearance below 3.0 mm (0.118 inch) at Position 1. Repeat the clamping process on the rack boot No.1. Use pliers to install both boot clips while tightening the lock nut and tie rod assembly LH to the rack end using matchmarks as the guide and complete the same procedure for the RH assembly. The procedure requires two new O-rings that need power steering fluid coating before their installation to the left turn pressure tube and next the use of special service tool: 09023-38200 to install the left turn pressure tube to the power steering rack and pinion assembly with 11 Nm (113 kgf-cm, 8 ft. lbs.) torque through a 250 mm (9.84 inch) torque wrench fulcrum followed by right turn pressure tube installation. Set the rack & pinion power steering rack and pinion assembly into place with two bolts and nuts while torquing it to 70 Nm (714 kgf-cm, 52 ft. lbs.). Then install the power steering rack housing heat insulator (3MZ-FE engine type) on the assembly. Attach the pressure feed tube assembly using special tool 09023-12700 while tightening it to 22 Nm (227 kgf-cm, 16 ft. lbs.) with a 300 mm (11.81 inch) torque wrench fulcrum and then apply the same method to the return tube assembly. Use the nut to fasten the tube clamp on the 2AZ-FE then torque it to 9.8 Nm (100 kgf-cm, 87 inch lbs.). For the 3MZ-FE engine type, install the tube clamp with the heat insulator and nut using 9.8 Nm (100 kgf-cm, 87 inch lbs.) torque and then secure the tube clamp with the bolt at the same torque. You should install the front stabilizer bracket No.1 LH while torquing its 2 bolts to 19 Nm (194 kgf-cm, 14 ft. lbs.). Follow this step by installing the bracket No.1 RH using the same torques. Follow the same procedure to install the front stabilizer link assemblies LH and RH then tie rod assemblies LH and RH. To complete the assembly, first install the front wheel while tightening to 103 Nm (1.050 kgf-cm, 76 ft. lbs.), then install the steering intermediate shaft assembly after aligning matchmarks then torquing the bolt to 35 Nm (360 kgf-cm, 26 ft. lbs.) and finally secure the clamp with a tightened bolt A on hole cover No.1. Following installation, the power steering fluid requires bleeding while technicians need to check for leaks and inspect and adjust front wheel alignment and conduct steering wheel center point inspection and steering angle sensor zero point calibration.