TOYOTA RAV4 1996 Service Repair Manual

7. Remove cylinder end stopper, turning counterclockwise. Remove "O" ring from stopper. See Fig. 18 .
8. Position rack housing vertically, and press oil seal and spacer from housing. See Fig. 18
.
Fig. 17: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 4WD &
4Runner Shown; Land Cruiser & Tundra Are Similar - 1 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 38 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 39 © 2005 Mitchell Repair Information Company, LLC.

Fig. 18: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 4WD &
4Runner Shown; Land Cruiser & Tundra Are Similar - 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, press oil seal from bearing guide nut. Coat NEW oil seal with power steering fluid and press
into bearing guide nut.
5. Check needle bearing of rack housing for pitting or wear. If faulty, replace rack housing. If okay, coat
inside of bearing with molybdenum disulfide lithium-base grease.
6. Inspect condition of control valve bearing. If worn or damaged, replace control valve assembly. If okay,
coat inside of bearing with molybdenum disulfide lithium-base grease.
7. Check inside of cylinder end stopper bushing. If faulty, replace bushing. If okay, coat inside of bearing
with molybdenum disulfide lithium-base grease.
8. 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.
9. 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.
10. 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 lip with power steering fluid. Press
seal and spacer into rack housing from end opposite control valve housing portion. See Fig. 18
. 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 rack housing oil seal lip with power steering fluid. Install seal into rack housing.
4. Coat NEW cylinder end stopper "O" ring with power steering fluid. Install cylinder end stopper and
tighten to specification. See TORQUE SPECIFICATIONS
. Stake rack housing at end stopper.
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 a leak, check installation of
oil seals at each end of housing. See Fig. 9
.
6. Coat Teflon rin
gs of control valve assembly with power steering fluid. Wrap serrated end of control valve

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 40 © 2005 Mitchell Repair Information Company, LLC.

shaft with tape. Push control valve assembly into housing. Coat NEW "O" ring with power steering fluid
and install into bearing guide nut. Install and tighten nut. See TORQUE SPECIFICATIONS
. Stake
guide nut.
7. Coat NEW control valve "O" ring with power steering fluid. Install into control valve housing. Align
reference marks for housings. Position control valve housing. Install and tighten mounting bolts. See
TORQUE SPECIFICATIONS
. Install dust cover.
8. Install rack guide, spring and rack guide spring cap. Apply thread lock sealant to cap threads.
Temporarily install cap.
9. Temporarily install both rack ends. Using a 21-mm wrench, tighten rack guide spring cap to 18 ft. lbs. (24
N.m). Loosen cap by 12 degrees on Tundra, or 19 degrees on all other models. With 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 11.5-16 INCH lbs.
(1.3-1.8 N.m) on Land Cruiser, 10.4-13.9 INCH lbs. (1.2-1.6 N.m) on Tundra, or 4.1-14.9 INCH lbs.
(0.5-1.7 N.m) on all other models, measured with torque wrench on control valve stem. See Fig. 11
.
10. 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.
11. 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 56 ft. lbs. (76 N.m). Stake claw
washers.
12. 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.
13. 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
.
14. Install NEW union seats into housing fittings. Install 2 turn pressure tubes. Tighten fittings to
specification. See TORQUE SPECIFICATIONS
.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (LAND CRUISER)
ApplicationFt. Lbs. (N.m)
Power Steering Pump
Mounting Bolts/Nut13 (17)
Power Steering Pulley Nut32 (43)
Pressure Feed Tube Union Bolt42 (56)
Pressure Port Union61 (83)
Rear Housing Bolts17 (23)
Rack & Pinion
Assembly Mounting Bolts/Nuts74 (100)
Bearing Guide Nut19 (25)
Control Valve Housing-To-Rack Housing Bolts13 (18)
Control Valve Housing-To-Pressure Feed Tube36 (49)
Control Valve Stem-To-Intermediate Shaft Clamp Bolt26 (35)
Cylinder End Stopper49 (65)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 41 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS (RAV4)
TORQUE SPECIFICATIONS (SIENNA)
Rack End56 (76)
Rack Guide Spring Cap Lock Nut51 (69)
Tie Rod End Lock Nuts41 (56)
Tie Rod End Nuts53 (72)
ApplicationFt. Lbs. (N.m)
Exhaust Pipe-To-Manifold Nuts45 (61)
Front Suspension Crossmember
Control Arm End Bolts/Nuts94 (127)
Inner Lower Nuts82 (112)
Inner Upper Bolts152 (206)
Lower Suspension Arm Bracket101 (137)
Power Steering Pump
Air Control Valve27 (37)
Bracket Bolts32 (43)
Pressure Port Union51 (69)
Pulley Nut32 (43)
Return Port Union Bolt(1)
Pressure Feed Tube Fitting32 (43)
Pressure Feed Tube Mounting Bolt(1)
Pressure Feed Tube Union Bolt38 (52)
Rack & Pinion
Assembly Mounting Bolts83 (113)
Rack Guide Spring Cap Lock Nut32 (43)
Rack Housing Cap51 (69)
Rack Housing Lock Nut(1)
Rack Housing No. 1 Bracket Bolt45 (61)
Steering Rack End61 (83)
Turn Pressure Tube Fittings22 (30)
Turn Pressure Tube Union Nuts22 (30)
Stabilizer Bar End Mounting Nuts
4-Door Models54 (73)
2-Door Models33 (45)
Tie Rod End Lock Nuts41 (56)
Tie Rod Ends36 (49)
(1)Tighten to 115 INCH lbs. (13 N.m).
ApplicationFt. Lbs. (N.m)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 42 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS (TACOMA 2WD)
Power Steering Pump
Air Control Valve27 (37)
Front Bracket Bolts32 (43)
Mounting & Adjusting Bolts32 (43)
Pressure Port Union62 (84)
Pulley Nut32 (43)
Rear Housing Bolts12 (16)
Return/Suction Port Union Bolt(1)
Pressure Feed Tube-To-Pump Fitting18 (24)
Pressure Feed Tube Union Bolt38 (52)
Rack & Pinion
Assembly Mounting Bolts134 (182)
Control Valve Housing-To-Rack Housing Bolts13 (18)
Control Valve Stem-To-Intermediate Shaft Clamp Bolt26 (35)
Rack Housing Cap43 (58)
Rack Housing Self-Locking Nut18 (24)
Rack Housing No. 2 Bracket Nut(2)
Stabilizer Bar End Mounting Nuts14 (19)
Steering Rack End61 (83)
Tie Rod End Lock Nuts54 (73)
Tie Rod End Nuts36 (49)
Tube Fittings
Control Valve Housing-To- Rack Fitting(1)
Housing-To-Pump18 (24)
INCH Lbs. (N.m)
Pressure Feed Tube-To-Body Mounting Bolt69 (7.8)
(1)Tighten to 115 INCH lbs. (13 N.m).
(2)Tighten to 89 INCH lbs. (10 N.m).
ApplicationFt. Lbs. (N.m)
Power Steering Pump
Bracket Bolts (V6)32 (43)
Mounting Bolts/Nut
4-Cylinder29 (39)
V632 (43)
Power Steering Idler Pulley Bolt29 (39)
Pressure Feed Tube Union Bolt34 (46)
Pressure Port Union61 (83)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 43 © 2005 Mitchell Repair Information Company, LLC.

TORQUE SPECIFICATIONS (TACOMA 4WD, TUNDRA & 4RUNNER)
Rear Housing Bolts17 (23)
Reservoir Mounting Bolts
Front(1)
Rear17 (23)
Pressure Feed Tube-To-Pump Union Bolt34 (46)
Rack & Pinion
Assembly Mounting Bolts/Nuts148 (201)
Control Valve Housing-To-Rack Housing Bolts13 (18)
Control Valve Housing-To-Rack Tube Fitting(1)
Control Valve Stem-To-Intermediate Shaft Clamp Bolt26 (35)
Rack End61 (83)
Rack Guide Spring Cap Lock Nut51 (69)
Rack Housing Cap43 (58)
Rack Housing No. 2 Bracket Bolt45 (61)
Rack Housing Self-Locking Nut18 (24)
Tie Rod End Lock Nuts40 (54)
Tie Rod End Nuts53 (72)
(1)Tighten to 115 INCH lbs. (13 N.m).
ApplicationFt. Lbs. (N.m)
Power Steering Pump
Bracket Bolts (V6)32 (43)
Mounting Bolts/Nut
4-Cylinder29 (39)
V632 (43)
Power Steering Idler Pulley Bolt29 (39)
Pressure Feed Tube Union Bolt34 (46)
Pressure Port Union61 (83)
Rear Housing Bolts17 (23)
Reservoir Mounting Bolts
Front(1)
Rear17 (23)
Pressure Feed Tube-To-Pump Union Bolt34 (46)
Rack & Pinion
Assembly Mounting Bolts/Nuts123 (167)
Bearing Guide Nut18 (24)
Control Valve Housing-To-Rack Housing Bolts13 (18)
Control Valve Housing-To-Rack Tube Fitting18 (24)
Control Valve Stem-To-Intermediate Shaft Clamp Bolt26 (35)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 44 © 2005 Mitchell Repair Information Company, LLC.

Cylinder End Stopper58 (79)
Rack End56 (76)
Rack Guide Spring Cap Lock Nut51 (69)
Rack Housing Bracket Bolt/Nut123 (167)
Tie Rod End Lock Nuts41 (56)
Tie Rod End Nuts67 (91)
(1)Tighten to 115 INCH lbs. (13 N.m).

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 45 © 2005 Mitchell Repair Information Company, LLC.

1999-2000 SUSPENSION
Rear - Front Wheel Drive
DESCRIPTION
On Avalon, Camry, Camry Solara, Celica and Corolla models, rear suspension components are strut assemblies
or shock absorbers with coil springs, connected between rear axle carrier or lower suspension arm, and vehicle
body. Wheel bearings and the axle hub is a one piece assembly, bolted to rear axle carrier. See Fig. 1
or Fig. 2 .

1999 Toyota RAV4
1999-2000 SUSPENSION Rear - Front Wheel Drive

1999 Toyota RAV4
1999-2000 SUSPENSION Rear - Front Wheel Drive
Microsoft
Sunday, November 22, 2009 10:37:21 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, November 22, 2009 10:37:26 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Exploded View Of Rear Suspension Components (Avalon Shown; Camry, Camry Solara, 1999
Celica & Corolla Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 2: Exploded View Of Rear Suspension Components (2000 Celica)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 SUSPENSION Rear - Front Wheel Drive
Microsoft
Sunday, November 22, 2009 10:37:21 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.