LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Toyota >> 2004 >> RAV4 Base, AWD, Standard >> Repair and Diagnosis >> Steering >> Power Steering >> Power Steering Gear >> Reassembly
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Power Steering Gear: Reassembly

  1. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL 
    1. Apply power steering fluid to a new oil seal, and install the oil seal on the rack housing at an angle.
      NOTE: Install the oil seal in the correct direction.

      HINT:

      Install the oil seal so that the port faces downward with approx. 15 degrees.

    2. Using SST, push in the oil seal by hand until it passes through the 2 ports.

      SST 09631-00180, 09950-70010 (09951-07360)

      NOTE: Do not turn SST when inserting the oil seal.
      Fig 1: Installing Power Steering Cylinder Tube Oil Seal
      G02926290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After the oil seal has passed through the ports, push in the oil seal by hand until it becomes level, using SST.

      SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)

      Fig 2: Pushing Oil Seal By Hand Until It Becomes Level
      G02926291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When SST is set, do not damage the inside surface of the rack housing.
    4. After the oil seal has become level, using SST and press, install the oil seal.

      SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)

    5. Coat new oil seal lip with power steering fluid.
    6. Using needle nose pliers, install the bush to the rack housing.
      Fig 3: Installing Bush To Rack Housing
      G02926292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL POWER STEERING RACK 
    1. Coat a new power piston O-ring with power steering fluid and install it to the steering rack.
    2. Coat a new power piston oil seal with power steering fluid.
    3. Expand the power piston oil seal with your fingers.
      NOTE: Be careful not to over expand the power piston oil seal.
      Fig 4: Expanding Power Piston Oil Seal With Fingers
      G02926293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the power piston oil seal to the steering rack, and settle it down with your fingers.
      Fig 5: Installing Power Piston Oil Seal To Steering Rack
      G02926294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install SST to the steering rack.

      SST 09631-20102

      HINT:

      If necessary, scrape the burrs off the steering rack teeth end and burnish.

    6. Coat the SST with power steering fluid.
    7. Install the steering rack into the rack housing.
      8. Fig 6: Installing Steering Rack Into Rack Housing
      G02926295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the SST.

      SST 09631-20102

  3. INSTALL CYLINDER END STOPPER 
    1. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
    2. Coat a new cylinder end stopper oil seal lip with power steering fluid.
    3. Install the cylinder end stopper oil seal by pushing it into the rack housing without tilting.
      Fig 7: Installing Cylinder End Stopper Oil Seal
      G02926296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the oil seal is installed facing in the correct direction.
      • Be careful not to damage the oil seal lip.
    4. Coat a new O-ring with power steering fluid.
    5. Install the O-ring to the cylinder end stopper.
    6. Install a new rack guide bush to the cylinder end stopper.
    7. Apply molybdenum disulfide lithium base grease to the inside of the bush.
      Fig 8: Applying Grease To Inside Of Bush
      G02926297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Place rack housing in vise.
      NOTE: Hold the arrow part in Fig 9 in a vise.
    9. Using SST, install the cylinder end stopper to rack housing.

      SST 09631-20120

      Torque: 60 N.m (612 kgf.cm, 44 ft.lbf) 

      Fig 9: Installing Cylinder End Stopper To Rack Housing Using SST
      G02926298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT RACK & PINION POWER STEERING GEAR ASSEMBLY 
    1. Install SST to the rack housing.

      SST 09631-12071 (09633-00010)

      2. Fig 10: Installing SST To Rack Housing
      G02926299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply vacuum of 53 kPa (400 mmHg, 15.75 in. Hg) for about 30 seconds.
    3. Check that there is no change in the vacuum.

      If there is a change in the vacuum, check the installation of the oil seals.

  5. INSTALL CONTROL VALVE ASSEMBLY 
    1. Coat the teflon rings and oil seal lip with power steering fluid.
    2. Coat the bearing with molybdenum disulfide lithium base grease.
    3. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
    4. Using SST, press the control valve assembly into the control valve housing.

      SST 09612-22011

      Fig 11: Installing Control Valve Assembly Using SST
      G02926300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the teflon rings and oil seal lips.
  6. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY 
    1. Install a new gasket.
    2. Align the matchmarks on the control valve housing and rack housing.
    3. Push into the control valve housing with control valve assembly.
    4. Install the 2 bolts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

      5. Fig 12: Aligning Matchmarks On Control Valve Housing And Rack Housing, Installing Bolts
      G02926301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL RACK GUIDE SUB-ASSEMBLY 
    1. Apply molybdenum lithium base grease to the contact surface of the power steering rack and of the rack guide.
    2. Install the rack guide and compression spring to the rack housing.
    3. Apply sealant to 2 or 3 threads of the rack guide spring cap.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    4. Temporarily install the rack guide spring cap.
  8. ADJUST TOTAL PRELOAD 
    1. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
    2. Using a hexagon wrench (24 mm), torque the rack guide spring cap.

      Torque: 83 N.m (851 kgf.cm, 62 ft.lbf) 

    3. Using a hexagon wrench (19 mm), return the rack guide spring cap 12°
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.
    5. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
    6. Using SST, a torque wrench hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification.

      SST 09616-00010

      Preload (turning): 

      1.0 to 1.6 N.m (10 to 17 kgf.cm, 9 to 15 in.lbf) 

  9. INSTALL STEERING RACK END SUB-ASSEMBLY 
    1. Install 2 new claw washers, and temporally install the rack ends.

      HINT:

      Align the claws of the claw washer with the steering rack grooves.

    2. Apply MP grease to the rack end ball joint.
    3. Using 2 SST, install the rack end sub-assy (RH side).

      SST 09922-10010

      Fig 13: Installing Steering Rack End Sub Assembly Using SST
      G02926302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 72 N.m (736 kgf.cm, 53 ft.lbf) 

      NOTE: Use SST 09922-10010 in the direction shown in Fig 13.

      HINT:

      • Using SST, hold the rack and install the rack end sub-assy.
      • Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).
    4. Using SST and a spanner (22 mm), tighten the rack end (LH side).

      Torque: 72 N.m (736 kgf.cm, 53 ft.lbf) 

      NOTE: Use SST 09922-10010 in the direction shown in Fig 13.

      HINT:

      • Using SST, hold the rack and install the rack end.
      • Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).
    5. Using a brass bar and a hammer, stake the 2 claw washers.
      NOTE: Avoid any impact to the steering rack.
      Fig 14: Staking Claw Washers Using Brass Bar And Hammer
      G02926303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Ensure that the steering rack hole is not clogged with grease.
      Fig 15: Ensuring Steering Rack Hole Is Not Clogged With Grease
      G02926304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.

  10. INSTALL STEERING RACK BOOT NO. 2 
    1. Apply silicon grease to the inside small caliber of steering rack boots No. 2
      2. Fig 16: Identifying Steering Rack Boot
      G02926305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the steering rack boots No. 2 to the groove on the rack housing.
  11. INSTALL STEERING RACK BOOT NO. 1 

    HINT:

    Install the rack boot No. 1 by the same procedures with rack boot No. 2.

  12. INSTALL STEERING RACK BOOT NO. 2 CLAMP 
    1. Using pliers and a screwdriver, install a new rack boot No. 2 clamp.
      Fig 17: Installing New Steering Rack Boot No. 2 Clamp
      G02926306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage or twist the rack boot.
  13. INSTALL STEERING RACK BOOT NO. 1 CLAMP 

    HINT:

    Install the rack boot No. 1 clamp by the same procedures with rack boot No. 2 clamp.

  14. INSTALL STEERING RACK BOOT CLIP 
    1. Using pliers, install the 2 boot clips.
    2. Using SST, turn the control valve, and check that the rack boots expand and contract smoothly.

      SST 09616-00011

      Fig 18: Checking Expanding And Contracting Of Rack Boots
      G02926307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL TIE ROD END SUB-ASSEMBLY LH 
    1. Screw the lock nut and tie rod end sub-assy LH onto the rack end until the matchmarks are aligned.
      Fig 19: Installing Tie Rod End Sub-Assembly LH
      G02926308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      After adjusting toe-in, torque the lock nut.

  16. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Install the RH side by the same procedures with LH side.

scientia non olet · About LEMON Manuals