Toyota RAV4 1999 Manual page 37

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)
NOTE: When removing oil seals, be sure to note direction seals are facing for
reinstallation in same direction.
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.
1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks