TOYOTA RAV4 1996 Service Repair Manual

1. Secure rack and pinion housing in soft-jaw vise (DO NOT over-tighten vise). Remove 2 turn pressure
tubes and "O" rings. See Fig. 12
.
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. 13
. Holding steering rack, remove rack ends. Mark left
and right sides for proper reinstallation. Remove washers.
4. Remove rack guide spring cap lock nut. See Fig. 12
. Remove rack guide spring cap, spring and rack
guide sub-assembly.
5. Remove rack housing cap from lower side of housing. Hold shaft from rotating, and remove self-locking
nut from top end of control valve shaft. Remove dust cover from upper side of housing. See Fig. 12
.
6. Place reference marks on valve housing and rack housing. Remove mounting bolts, valve housing and
gasket. Tape serrated end of valve shaft. Invert housing on protected blocks and press control valve
assembly, with oil seal, out of housing. Remove oil seal from control valve assembly.
7. Place reference marks on No. 2 mounting bracket and rack housing. Pry bracket clamp apart, and remove
bracket and grommet.
8. Remove cylinder end stopper, turning clockwise, until wire end is visible in service hole. Turn cylinder
end stopper counterclockwise and remove wire. See Fig. 13
and Fig. 14. 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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Fig. 12: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Sienna - 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. 13: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Sienna - 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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Fig. 14: Removing Cylinder End Stopper (Sienna)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. Using brass bar and hammer, tap rack and bushing out of housing. Remove bushing from rack. Remove
"O" ring from bushing. See Fig. 13
. Press oil seal from rack housing.
Inspection
1. With rack mounted horizontally on "V" blocks, use dial indicator to measure rack runout. Runout should
not exceed .012" (.30 mm). Check rack and teeth for wear and damage. Replace rack if necessary.
2. If necessary, press oil seal and bearing from control valve housing. Coat NEW seal lip with power
steering fluid. Press seal into place. Ensure oil seal is facing same direction as removed.
3. Coat NEW bushing with molybdenum disulfide lithium-base grease. Using press, install bearing against
oil seal in rack housing.
4. If necessary, use brass bar and hammer to tap lower bearing out of rack housing. See Fig. 12
. Turn
housing over, and use press to press upper bearing out of rack housing.
5. If necessary, use puller to remove oil seal from rack end bushing. See Fig. 12
. Coat NEW oil seal lip
with power steering fluid. Press seal into bushing.
6. If necessary, use screwdriver to remove Teflon ring and "O" ring from steering rack. Coat NEW "O" ring
with power steerin
g fluid. Install "O" ring. Carefully expand NEW Teflon ring by hand, only enough to

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1999-2000 STEERING Power Rack & Pinion - Trucks
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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.

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1999-2000 STEERING Power Rack & Pinion - Trucks
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15. Ensure steering rack hole (next to rack end) is not clogged with grease. Clean as necessary. Install boots
and clamps. Pinch clamps until there is .08" (2.0 mm), or less, clearance between clamp ends.
16. 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
.
17. Install 2 NEW "O" rings, coated with power steering fluid, and 2 turn pressure tubes. Tighten fittings to
specification. See TORQUE SPECIFICATIONS
.
Disassembly (Tacoma 2WD)
1. Secure rack and pinion housing in soft-jawed vise (DO NOT over-tighten vise). Remove 2 turn pressure
tubes and 4 "O" rings. See Fig. 15
.
2. Place reference marks on tie rod end and rack end, across lock nut. Remove lock nuts and tie rod ends.
Loosen boot clamps. Mark and remove left and right side rack boots.
3. Unstake claw washer on both rack ends. See Fig. 16
. 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, bracket and
grommet.
5. Remove rack guide spring cap lock nut. See Fig. 15
. 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 self-locking nut from lower end of control
valve shaft. Remove dust cover from upper side of housing. See Fig. 15
.
7. Place reference marks on valve housing and rack housing. Remove mounting bolts and pull control valve
assembly and housing from rack housing.
8. Tape serrated end of control valve shaft. Press control valve assembly and oil seal from housing. Remove
oil seal from control valve.
9. Remove cylinder end stopper, turning clockwise, until wire end is visible in service hole. Turn cylinder
end stopper counterclockwise and remove wire. See Fig. 14
.
10. Using an extension bar and 19-mm socket wrench, press steering rack and bushing from housing.
Remove bushing from rack. Remove "O" ring from bushing. Press oil seal from rack housing. See Fig.
16 . 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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Fig. 15: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 2WD - 1 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 16: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 2WD -2 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
1. With rack mounted horizontally on "V" blocks, use dial indicator to measure rack runout. Runout should
not exceed .012" (.30 mm). Check rack and teeth for wear and damage. Replace rack if necessary.
2. If necessary, press oil seal and bearing from control valve housing. Coat NEW seal lip with power
steering fluid. Press seal into place. Ensure oil seal is facing same direction as removed.
3. Coat NEW bushing with molybdenum disulfide lithium-base grease. Using press, install bushing against
oil seal in rack housing.
4. If necessary, use brass bar and hammer to tap lower bearing out of rack housing. See Fig. 15
. Turn
housing over and press upper bearing out of rack housing.
5. Coat NEW lower bearing with molybdenum disulfide lithium-base grease. Using press, install NEW
bearing into lower side of rack housing. Turn housing over, coat NEW upper bearing with molybdenum
disulfide lithium-base grease. Using press, install bearing into upper side of rack housing.
6. If necessary, use puller to remove oil seal from rack end bushing. See Fig. 16
. Coat NEW oil seal lip
with power steering fluid. Press seal into bushing.
7. 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 firmly into rack groove.
8. 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.
9. If necessary, use screw extractor to remove union seats from side of control valve housing. Carefully tap
NEW seats into place.
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. 16
. Ensure oil seal
faces in proper direction.
2. Mount rack housing horizontally in vise. Clean rack teeth of any burrs. Place protective sleeve 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, and install on rack bushing. Tape steering rack end and
coat end with power steering fluid. Install rack bushing. Remove tape.
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. 14
.
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. Coat Teflon rings of control valve assembly with power steering fluid. Wrap serrated end of control valve
shaft with tape. Push control valve assembly into housing. Press NEW oil seal into place after coating lip

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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with power steering fluid.
7. Place NEW gasket on rack housing. Position control valve housing. Install and tighten mounting bolt. See
TORQUE SPECIFICATIONS
. Hold control valve shaft from turning, and install NEW self-locking
nut on lower end of shaft. Install dust cover.
8. 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.
9. Install rack guide seat to guide. Apply thread lock sealant to 2-3 threads of rack guide spring cap. 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. Loosen rack guide spring cap until rack guide spring is not functioning. Tighten rack
guide spring cap until preload is within 7.8-13.0 INCH lbs. (0.9-1.5 N.m), measured with torque wrench
on control valve stem. See Fig. 11
.
11. Apply thread lock sealant to rack guide spring cap lock nut. 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 No. 2 rack housing bracket and grommet. Align reference marks. Install
and tighten bolt. See TORQUE SPECIFICATIONS
.
13. 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.
14. Ensure steering rack hole (next to rack end) is not clogged with grease. Clean as necessary. Install boots,
clamps and clips. Pinch clamp until there is .08" (2.0 mm) or less 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 "O" rings coated with power steering fluid. Tighten fittings to
specification. See TORQUE SPECIFICATIONS
.
Disassembly (Land Cruiser, Tacoma 4WD, Tundra & 4Runner)
1. Secure rack and pinion housing in soft-jaw vise (DO NOT over-tighten vise). Remove 2 turn pressure
tubes. Remove union seats from fittings. See Fig. 17
.
2. Place reference marks on tie rod ends and rack ends, across lock nuts. Remove lock nuts and tie rod ends.
Remove boot clips and clamps. Mark and remove left and right side rack boots.
3. Unstake claw washer on both rack ends. See Fig. 18
. Holding steering rack, use appropriate removal tool
to remove rack ends. Mark left and right sides for proper reinstallation.
4. Remove rack guide spring cap lock nut. See Fig. 17
. Remove rack guide spring cap, spring and rack
guide. Remove dust cover.
5. Place reference marks on valve housing and rack housing. Remove mounting bolts, and pull control valve
assembly and housing from rack housing. Remove "O" ring from rack housing.
6. Loosen bearing guide nut. See Fig. 17
. Tape serrated end of control valve shaft. Tap control valve
assembly and bearing guide nut from housing. Remove nut. Remove "O" ring from nut. NOTE: When removing oil seals, be sure to note direction seals are facing for
reinstallation in same direction.

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