accommodate installation. Coat Teflon ring with power steering fluid. Press ring firmly into rack groove.
7. 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.
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. 13
. 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 "O" ring with power steering fluid. Install "O" ring on rack end bushing. Wrap tape on end of
steering rack (opposite of control valve housing end). Install bushing into rack housing. See
Fig. 12
.
4. Align hole for wire of cylinder end stopper with slot of rack housing. Use installer tool and turn stopper
clockwise 400-500 degrees. See
Fig. 13
.
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 there is, check installation of oil seals
at each end of housing. See
Fig. 9
.
6. Install grommet into rack housing bracket. Align nub on grommet with hole in bracket. Place bracket in
vise, and tighten clamp in place.
7. Wrap serrated end of control valve shaft with tape. Coat Teflon rings with power steering fluid. Install
control valve assembly into rack housing. Press NEW oil seal into place after coating lip with power
steering fluid.
8. Place NEW gasket on rack housing. Align reference marks and position valve housing to rack housing.
Install and tighten bolts to specifications. See
TORQUE SPECIFICATIONS
.
9. Hold control valve shaft bottom end to prevent turning. Install NEW self-locking nut on top end of shaft.
Tighten to specifications. See
TORQUE SPECIFICATIONS
. Install dust cover.
10. Apply thread lock sealant to 2-3 threads of rack housing cap. Install and tighten cap to specification. See
TORQUE SPECIFICATIONS
. Stake cap in 2 places.
11. Apply thread lock sealant to 2-3 threads of rack guide spring cap. Install rack guide sub-assembly, spring
and cap. Temporarily tighten cap.
12. Temporarily install both rack ends. Tighten rack guide cap to 18 ft. lbs. (24 N.m). Using wrench on rack
guide cap, loosen cap by 12 degrees. Using torque wrench on top end of control valve stem, turn stem
right and left 1-2 times. Using wrench, loosen rack guide spring cap until rack guide spring is not
functioning. Tighten rack guide spring cap until preload is within 6.9-12.2 INCH lbs. (0.8-1.4 N.m),
measured with torque wrench on control valve stem.
13. Apply thread lock sealant to rack guide spring cap lock nut. Using wrench to hold spring cap from
rotating, use torque wrench to tighten lock nut to specification. See
TORQUE SPECIFICATIONS
.
Recheck preload.
14. Remove both rack ends. Install NEW claw washers on each end of rack. Align claws with grooves in
rack. Install rack ends. Hold rack from turning, and tighten rack ends to 44 ft. lbs. (60 N.m). Stake claw
washers.
1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AM
Page 32
© 2005 Mitchell Repair Information Company, LLC.
