OEM 2005 Toyota RAV4 Rack And Pinion

2005 Toyota RAV4 Rack And Pinion Parts Q&A

• Q: How to disassemble the Rack And Pinion on 2005 Toyota RAV4?

  A: When removing the rack and pinion from its components do not use excessive force with the vise. Use SST 09023-38200 to take out both pressure tubes that make two turns. You should mount the rack and pinion assembly into SST 09612-00012 while it sits in a vise. The tie rod ends must be removed along with their corresponding lock nuts after both sides receive their matchmarks then the lock nuts get loose and the ends get removed followed by marking the removed ends. Proceed by loosening the clamp screw to detach all RH and LH clips, clamps, and rack boots with caution to prevent damage to the boots and marking the RH and LH rack boots. The technician removes the RH and LH rack ends and claw washers through claw washer unstaking with a screwdriver and hammer, 22 mm spanner rack and pinion holding, and SST 09922-10010 end removal. This process is repeated for the other side keeping RH and LH rack end markings. Placing matchmarks allows you to first remove the bolt and bracket from the No. 1 rack housing bracket followed by removing its grommet. SST 09922-10010 helps disassemble the lock nut of the rack guide spring cap and subsequent removal of all elements including rack guide spring cap, rack guide spring, conical spring and rack guide through the use of a 21 mm hexagon wrench. Use SST 09616-00011 to remove the rack housing cap and self-locking nut before extracting the control valve assembly, upper oil seal and upper bearing by using snap ring pliers and SST 09613-12010 and avoid tapping out the control valve during this process. Use a brass bar to separate the cylinder end stopper and rack and pinion with the oil seal before inspecting the rack and pinion for runout, teeth wear and damage as well as checking the back surface for wear and damage since repair of the rack and pinion may be necessary. Inspect control valve components for proper dimensionality after which replacement of components should take place. To make a replacement install the new lower bearing on the control valve shaft by removing it with a brass bar and hammer then applying molybdenum disulfide lithium base grease before putting it into the rack housing. To replace the oil seal of the rack housing that secures the control valve shaft assembly users should extract the old oil seal with SST 09950-60010 (09951-00260), apply power steering fluid to the new oil seal lip before pressing it into place using SST 09950-60010 (09951-00230, 09951-00400, 09952-06010). To replace the control valve assembly bushing along with its lower oil seal make sure to use SST 09612-24014 (09613-22011). Avoid contact damage to the rack housing while using a screwdriver with vinyl tape around it to prevent seal damage. Coat a new oil seal lip with power steering fluid before pressing it in with SST 09950-60010 (09951-00230, 09951-00340, 09952-06010). First apply power steering fluid to a new oil seal lip before installing it with SST 09950-60010 (09951-00230, 09951-00340, 09952-06010) to complete the installation. The installation process requires using a screwdriver to take out the Teflon ring and O-ring from the rack and pinion followed by O-ring coating with power steering fluid, Teflon ring expansion and installation but the groove must be kept undamaged. The operation involves you to use a screwdriver to remove existing Teflon rings from the control valve assembly then expand new rings before coating them with power steering fluid and installing them without harming the Teflon rings. Install new union seats through an extension bar and hammer with screw extractor once the dust has been removed from the rack housing. Place power steering fluid or molybdenum disulfide lithium base grease onto the designated parts before using SST 09631-16020 to set the rack and pinion into position and wiping SST with power steering fluid before removing SST. Install the oil seal through the rack housing while maintaining perfect alignment because this will determine its proper orientation. Step one requires using SST 09612-22011 to drive in the cylinder end stopper. Then install a new snap ring. Apply a 53kPa (400mmHg, 15.75inchHg) vacuum examination for thirty seconds to check if there is any change in vacuum pressure. You must install the control valve assembly into the rack housing before inserting a new upper bearing that received molybdenum disulfide lithium base grease treatment with SST 09612-22011. Then, position and install a new upper oil seal in the correct direction following the press-in of a new snap ring. The procedure involves stopping the control valve shaft rotation through use of SST 09616-00011 to achieve 12 Nm torque (125 kgf-cm, 9 ft. lbs.). Next, measure dimension "A" with SST 09613-12020 followed by staking the self-locking nut. Apply Part No. 08833-00080, Three Bond 1344, Loctite 242 or equivalent sealant to the rack housing cap before torquing it to 69 Nm (700 kgf-cm, 51 ft. lbs.). The rack guide assembly requires correct arrangement of the conical spring with a sealant application on the rack guide spring cap before installation. The adjustment process requires attaching the RH and LH rack ends temporarily then torquing the rack guide spring cap to 25 Nm (250 kgf-cm, 18 ft. lbs.) and returning it to 12° while turning the control valve shaft with SST 09616-00011 and loosening the spring cap until non-function followed by tightening to reach the specified preload range (1.1 to 1.6 Nm, 11 to 16 kgf-cm, 9.7 to 14.2 inch lbs.). The rack guide spring cap needs an application of sealant before installing a lock nut using SST 09922-10011 to achieve torque of 32 Nm (330 kgf-cm, 24 ft. lbs.). Recheck the total preload after this stage. First install fresh claw washers and rack ends onto the RH and LH rack and pinion then join the claws to the rack and pinion grooves before tightening the rack end to 60 Nm through SST 09922-10010 and performing stake washers followed by the LH side installation. The installation concludes with aligning matchmarks on the grommeted No. 1 rack housing bracket before torquing the bolt to 61 Nm (620 kgf-cm, 45 ft. lbs.). Next, fit the RH and LH rack boots followed by clamps and clips where the rack and pinion hole needs grease clearance until a proper clamp tightened state is achieved. This procedure must then be duplicated on the opposite side. Place the 2-turn pressure tubes using SST 09023-38200 then torque them to 27 Nm (270 kgf-cm, 20 ft. lbs.).