Inspection
1. With rack mounted horizontally on "V" blocks, use dial indicator to measure rack runout. Runout should
not exceed .012" (.3 mm). Check rack and teeth for wear and damage. Replace rack if necessary.
2. Using cylinder gauge, measure inside diameter of rack housing bushing. Maximum diameter should not
exceed 1.11" (28.2 mm). Using micrometer, measure outside diameter or control valve. Minimum
diameter should not exceed 1.09" (27.69 mm). Replace components if necessary.
3. If necessary, use puller to extract bushing from rack housing. Using screwdriver, carefully tap oil seal
upward out of rack housing. Coat NEW seal lip with power steering fluid. Using seal installer, carefully
tap NEW seal into place from upper side of rack housing. Make sure oil seal is facing same direction as
removed.
4. Coat NEW bushing with molybdenum disulfide lithium-base grease. Using press, install bushing against
oil seal in rack housing.
5. If necessary, use screwdriver to remove Teflon ring and "O" ring from steering rack. Coat NEW "O" ring
with power steering fluid. Install "O" ring. Carefully expand NEW Teflon ring by hand, only enough to
accommodate installation. Coat Teflon ring with power steering fluid. Press ring into rack groove. Use
ring installer to fully seat ring.
6. If necessary, use screwdriver to remove 4 Teflon rings from control valve assembly. Coat NEW rings
with power steering fluid. Slightly expand rings by hand, and install in each groove. Use installer tool to
slide over rings and fully seat them.
7. If necessary, use screw extractor to remove 2 union seats from rack housing. See
Fig. 7
. Use drift and
hammer to tap in 2 NEW union seats.
8. Check cylinder end stopper bushing for wear or damage. If necessary, replace cylinder end stopper
(bushing is not replaceable separately). Coat inside of bushing with molybdenum disulfide lithium-base
grease.
Reassembly
1. With rack housing mounted vertically in soft-jaw vise, coat NEW seal with power steering fluid, and
press into rack housing from end opposite control valve housing portion. See
Fig. 8
. Ensure oil seal faces
in proper direction.
2. Mount rack housing horizontally in vise. Clean rack teeth of any burrs. Place protective end piece on
steering rack teeth end. Coat protective sleeve with power steering fluid. Install steering rack into rack
housing. Remove protective sleeve.
3. Coat NEW oil seal lip with power steering fluid. Wrap tape on end of steering rack (opposite of control
valve housing end). Push oil seal evenly into rack housing. See
Fig. 8
.
4. Install end stopper into rack housing. Install NEW snap ring.
5. Install special connectors onto union fittings of rack housing, and attach hand vacuum pump. Apply
15.75" Hg for about 30 seconds. Ensure there is no vacuum leak. If leak exists, check installation of oil
seals at each end of housing. See
Fig. 9
.
1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AM
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© 2005 Mitchell Repair Information Company, LLC.
