TOYOTA RAV4 1996 Service Repair Manual

pump rotating torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less.
2. While holding pulley, remove pulley nut. Remove fluid reservoir. Remove and discard "O" ring.
3. Remove union bolt and "O" ring from pressure port. Remove flow control valve and spring. See Fig. 6
.
Remove pump bracket.
4. Remove rear housing bolts and 2 "O" rings. Remove wave washer, side plate and gasket.
5. Remove cam ring and 10 vane plates. See Fig. 6
. Remove snap ring and pump rotor. Remove pump
shaft. Remove 2 straight pins from front housing.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 6: Exploded View Of Power Steering Pump (Tacoma & 4Runner V6 Shown; Land Cruiser &
Tundra Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing

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1999-2000 STEERING Power Rack & Pinion - Trucks
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shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm).
Clearance should not exceed .0028" (.071 mm). If clearance exceeds maximum, replace front housing and
pump shaft.
2. Using micrometer, measure height, thickness and length of 10 vane plates. See VANE PLATE
SPECIFICATIONS table. Use feeler gauge to measure clearance between rotor groove and plate.
Maximum clearance is .0014" (.035 mm). If clearance exceeds maximum, replace plate and/or rotor with
one having same mark stamp of "1", "2", "3", "4" or no marking.
3. Coat flow control valve with power steering fluid and check that it falls smoothly into valve hole on its
own weight.
4. Check flow control valve for leakage by closing one hole and applying 57-71 psi (4-5 kg/cm2) air
pressure to opposite hole. Air should NOT come out hole on end of valve. If valve does not respond as
indicated, replace valve with one having same letter mark as on front housing and/or on valve.
5. Using calipers, measure free length of flow control valve spring. Minimum free length is 1.307" (33.2
mm). If not within specification, replace spring.
6. If necessary, remove oil seal from housing. Coat NEW seal lip with power steering fluid and carefully
press NEW oil seal into position. Ensure seal is in same direction as removed.
Reassembly
1. Coat all internal components with power steering fluid. Install 2 NEW straight pins into front housing.
Install pump shaft.
2. Align holes of cam ring and 2 straight pins. Install cam ring, with mark facing outward. Install pump rotor
with mark facing outward. Install NEW snap ring on pump shaft. Install 10 vane plates, with round end
facing outward.
3. Install a NEW gasket on front housing. Install side plate, aligning holes with straight pins. Install wave
washer so protrusions fit into slots in side plate.
4. Coat 2 NEW "O" rings with power steering fluid. Install "O" rings into pump rear housing. Install rear
housing and tighten bolts to specification. See TORQUE SPECIFICATIONS
.
5. Install flow control spring and valve. Ensure valve is facing correct direction. Coat a NEW "O" ring with
power steering fluid. Install "O" ring to pressure port union. Tighten union to specification. See
TORQUE SPECIFICATIONS
.
6. Install pump bracket. Install fluid reservoir. Tighten bolts to specification. See TORQUE
SPECIFICATIONS .
7. Position and hold pump pulley and install nut. Tighten nut to specification. See TORQUE
SPECIFICATIONS . Measure pump rotating torque. Using a torque wrench, check pump rotating
torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less.
POWER RACK & PINION
Disassembly (RAV4)
NOTE: When removing oil seals, be sure to note direction seals are facing for
reinstallation in same direction.

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1999-2000 STEERING Power Rack & Pinion - Trucks
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1. Secure rack and pinion housing in soft-jaw vise (DO NOT over-tighten vise). Remove 2 turn pressure
tube union bolts, gaskets and tubes. See Fig. 7
.
2. Place reference marks on tie rod end and rack end. Loosen lock nut. Remove screw and loosen clamp.
Mark and remove left and right side rack boots.
3. Unstake claw washer on both rack ends. See Fig. 8
. Holding steering rack, use appropriate removal tool
to remove rack ends. Mark left and right sides for proper reinstallation.
4. Place reference marks on mounting bracket and rack housing. Remove retaining bolt. Remove bracket
and grommet.
5. Remove rack guide spring cap lock nut. See Fig. 7
. Remove rack guide spring cap, spring, rack guide
and seat. Remove seat from guide.
6. Remove rack housing cap from lower side of housing. Remove dust cover from upper side of housing.
See Fig. 7
.
7. Remove snap ring from inside rack housing, above control valve assembly. Using puller, remove control
valve with oil seal and bearing. Remove oil seal and bearing from control valve.
8. Remove bearing from lower side of rack housing. Mount rack vertically in vise. Remove snap ring from
end of rack housing. Press rack end stopper from rack housing. Remove oil seal from rack. See Fig. 8
.
Press oil seal from rack housin
g.

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1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 7: Exploded View Of Power Rack & Pinion Steering Gear Assembly (RAV4 - 1 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 8: Exploded View Of Power Rack & Pinion Steering Gear Assembly (RAV4 - 2 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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1999-2000 STEERING Power Rack & Pinion - Trucks
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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 housin
g. See Fig. 9.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 9: Performing Air Tightness Check
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Coat Teflon rings with power steering fluid. Install control valve assembly into rack housing. Press NEW
bearing into place on top of control valve. Press NEW oil seal into place after coating lip with power
steering fluid. Install NEW snap ring. See Fig. 7
. Install dust cover.
7. Press NEW bearing into lower side of rack housing. Install lock nut onto lower end of control valve
assembly. Tighten to specification. See TORQUE SPECIFICATIONS
. Using installer tool, box
wrench and crescent wrench, turn "C" to set dimension "A" to .65-.67" (16.5-17.0 mm). Stake nut by
turnin
g part "B" until it touches spacer of installer tool. See Fig. 10.

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1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 10: Installing & Setting Control Valve Lock Nut (RAV4)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
8. Apply thread lock sealant to 2-3 threads of rack housing cap. Install and tighten cap to specification. See
TORQUE SPECIFICATIONS
.
9. Install rack guide seat to guide. Install guide, spring, washer and cap. Temporarily tighten cap.
10. Temporarily install both rack ends. Using 21-mm wrench, tighten rack guide spring cap to 18 ft. lbs. (24
N.m). Loosen cap by 12 degrees. Using torque wrench on top end of control valve stem, turn stem right
and left 1-2 times. Using 21-mm wrench, loosen rack guide spring cap until rack guide spring is not
functioning. Tighten control valve stem and rack guide spring cap until preload is within 6.9-11.3 INCH
lbs. (0.8-1.3 N.m), measured with torque wrench on control valve stem. See Fig. 11
.

1999 Toyota RAV4
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Fig. 11: Setting Assembly Preload (RAV4)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
11. Apply thread lock sealant to rack guide spring cap lock nut. Using 21-mm wrench to hold spring cap from
rotating, use torque wrench to tighten lock nut to specification. See TORQUE SPECIFICATIONS
.
Recheck preload.
12. 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.
13. Install grommet in rack housing mounting bracket No. 1. Align reference marks, and install bracket.
Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS
.
14. Ensure steering rack hole (next to rack end) is not clogged with grease. Clean as necessary. Install boots,
clamps and clips. Tighten clamp bolts until there is .08" (2.0 mm) clearance between clamp ends.
15. Screw tie rod end lock nut onto tie rod until reference marks are aligned. Install left and right tie rod ends.
After adjusting toe-in, tighten lock nuts to specification. See TORQUE SPECIFICATIONS
.
16. Install 2 turn pressure tubes. Use NEW gaskets on union fittings. Tighten fittings to specification. See
TORQUE SPECIFICATIONS
.
Disassembly (Sienna)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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