I have an 04 Toyota Sienna that has a leaking sower steering rack right by the high pressure line…

I have an 04 Toyota Sienna that has a leaking sower steering rack right by the high pressure line unfortunately the rack and pinion is very rusty and it would be cheaper to buy a new rack and pinion then to buy a newer van, plus i love my van, so i want to replace it and it would be awesome to know what i'm getting in to because i don't have the budget to take it to a shop and i'd like to wrench on it myself. i'm watching Ericthecarguy's 2006 Honda Odyssey Power Steering Rack Replacement video to see a van's rack replacement but it would be awesome to at least see what up. I don't want you to make a video taking out out more to just watching you go through the steps kind of thing or even here if you can write it down or help me with research on trying to learn what to do. I guess i'm just trying to get steer in the right direction.

it is a job, as follows:
RACK & PINION POWER STEERING GEAR ASSY
OVERHAUL

NOTICE: When installing, coat the parts indicated by the arrows with power steering fluid or molybdenum disulfide lithium base grease.

INSPECT CENTER FRONT WHEEL
REMOVE FRONT WHEEL
SEPARATE TIE ROD ASSY LH SST 09628-62011
SEPARATE TIE ROD ASSY RH SST 09628-62011
HINT: Perform the same procedure on the other side.

SEPARATE STEERING INTERMEDIATE SHAFT ASSY

Zoom Sized for Print

Fix the steering wheel with the seat belt.

Zoom Sized for Print

Release the 3 springs and separate the dust cover.

Zoom Sized for Print

Place matchmarks on the intermediate shaft assy and power steering gear assy.
Remove the bolt and separate the intermediate shaft assy.
SEPARATE FRONT STABILIZER LINK ASSY LH
SEPARATE FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the other side.

Zoom Sized for Print

REMOVE FRONT STABILIZER BRACKET NO.1 LH
Remove the 2 bolts and remove the stabilizer bracket No.1.
REMOVE FRONT STABILIZER BRACKET NO.1 RH
HINT: Perform the same procedure on the other side.

DISCONNECT PRESSURE FEED TUBE ASSY

Zoom Sized for Print

Remove the clip and disconnect the return tube assy from the power steering gear assy.

Zoom Sized for Print

Using SST, disconnect the pressure feed tube assy from the power steering gear assy. SST 09023-12700

Zoom Sized for Print

Remove the bolt and separate the tube clamp.

Zoom Sized for Print

Remove the nut and separate the tube clamp.

Zoom Sized for Print

REMOVE RACK & PINION POWER STEERING GEAR ASSY
Remove the 2 bolts, nuts and the power steering gear assy.
NOTICE: Do not damage the 2 pressure tubes.

Zoom Sized for Print

REMOVE RETURN TUBE NO.2
Using SST, remove the return tube No.2. SST 09023-12700

Zoom Sized for Print

REMOVE STEERING LEFT TURN PRESSURE TUBE
Using SST, remove the left turn pressure tube. SST 09023-38200
Remove the 2 O-rings from the left turn pressure tube.
REMOVE STEERING RIGHT TURN PRESSURE TUBE SST 09023-38200
HINT: Perform the same procedure on the other side.

Zoom Sized for Print

FIX RACK & PINION POWER STEERING GEAR ASSY
Using SST, secure the power steering gear assy. SST 09612-00012
HINT: Tape the SST before use.

Zoom Sized for Print

REMOVE TIE ROD ASSY LH
Place matchmarks on the tie rod assy and rack end sub-assy.
Loosen the lock nut, and remove the tie rod assy and lock nut.
REMOVE TIE ROD ASSY RH
HINT: Perform the same procedure on the other side.

Zoom Sized for Print

INSPECT TIE ROD ASSY LH
Secure the tie rod assy in a vise.
Install the nut to the stud bolt.
Flip the ball joint stud back and forth 5 times.
Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.83 to 3.43 Nm (8.5 to 35.0 kgf-cm, 7.3 to 30.4 inch lbs.)
INSPECT TIE ROD ASSY RH
HINT: Perform the same procedure on the other side.

REMOVE STEERING RACK BOOT CLIP
Remove the 2 rack boot clips.
REMOVE STEERING RACK BOOT NO.2 CLAMP
Using pliers, remove the rack boot No.2 clamp.
NOTICE: Be careful not to damage the steering rack boot No.2.

REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT: Perform the same procedure on the other side.

REMOVE STEERING RACK BOOT NO.2
REMOVE STEERING RACK BOOT NO.1
REMOVE STEERING RACK END SUB-ASSY

Zoom Sized for Print

Using a screwdriver and a hammer, unstake the claw washer.
NOTICE: Avoid any impact to the power steering rack.

Zoom Sized for Print

Using 2 SST, remove the 2 steering rack end sub-assy and 2 claw washers. SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustration.
Securely hold the power steering rack end with a SST.
REMOVE RACK GUIDE

Zoom Sized for Print

Using SST, remove the rack guide spring cap nut. SST 09922-10010
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

Zoom Sized for Print

Using SST, remove the rack guide spring cap. SST 09631-10021
Remove the compression spring and the rack guide.
REMOVE POWER STEERING CONTROL VALVE

Zoom Sized for Print

Using a socket wrench (27 mm), remove the rack housing cap.

Zoom Sized for Print

Using SST, hold the control valve and remove the nut. SST 09616-00011

Zoom Sized for Print

Wind vinyl tape around the serrated part of the control valve.
Remove the dust cover from the control valve housing.

Zoom Sized for Print

Remove the 2 bolts and the control valve w/ control valve housing. Remove the gasket.

Zoom Sized for Print

To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
Using a plastic hammer, remove the control valve w/ oil seal from the control valve housing.
Remove the oil seal from the control valve.

Zoom Sized for Print

Using a screwdriver, remove the 4 control valve rings.
NOTICE: Be careful not to damage the grooves for the control valve rings.

Zoom Sized for Print

REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
Using SST and a press, remove the control valve upper bearing and control valve upper oil seal from the control valve housing. SST 09950-70010 (09951-07150), 09950-60010 (09951-00250)

Zoom Sized for Print

REMOVE CYLINDER END STOPPER
Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.
REMOVE POWER STEERING RACK

Zoom Sized for Print

REMOVE POWER STEERING RACK BUSH
Remove the rack bush from the power steering rack.
Using SST, remove the rack bush oil seal. SST 09527-21011, 09612-24014 (09613-22011)
Using a screwdriver, remove the O-ring from the rack bush.

Zoom Sized for Print

REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
Using SST and a press, remove the cylinder tube oil seal. SST 09950-70010 (09951-07360), 09950-60010 (09951-00290)

Zoom Sized for Print

REMOVE RACK STEERING PISTON RING
Using a screwdriver, remove the rack steering piston ring and O-ring.
NOTICE: Be careful not to damage the grooves for rack steering piston ring.

Zoom Sized for Print

INSPECT POWER STEERING RACK
Using a dial indicator, check the power steering rack for runout and for teeth wear and damage. Maximum runout: 0.3 mm (0.012 inch)
If necessary, replace the rack & pinion power steering gear assy.
Check the back surface for wear and damage. If necessary, replace the rack & pinion power steering gear assy.

Zoom Sized for Print

INSTALL RACK STEERING PISTON RING
Coat a new O-ring with power steering fluid and install it onto the power steering rack.
Expand a new rack steering piston ring with your fingers.
NOTICE: Be careful not to over expand the rack steering piston ring.

Coat a new rack steering piston ring with power steering fluid.

Zoom Sized for Print

Install the rack steering piston ring onto the power steering rack, and settle it down with your fingers.

Zoom Sized for Print

INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
Coat a new cylinder tube oil seal lip with power steering fluid.
Using SST and a press, install the cylinder tube oil seal. SST 09950-60010 (09951-00420, 09951-00250, 09952-06010), 09950-70010 (09951-07360)
NOTICE:
Make sure that the cylinder tube oil seal is installed facing in the correct direction.
Take care so that the cylinder tube oil seal will not be reversed as you install it.

Zoom Sized for Print

INSTALL POWER STEERING RACK
Install SST onto the power steering rack. SST 09631-33010
HINT: If necessary, scrape the burrs off the power steering rack teeth end and burnish.

Coat the SST with power steering fluid.
Install the power steering rack into the rack housing.
Remove the SST.

Zoom Sized for Print

INSTALL POWER STEERING RACK BUSH
Using SST and a press, install the rack bush oil seal onto the rack bush. SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)
NOTICE: Make sure that the rack bush oil seal is installed facing in the correct direction.

Coat a new O-ring with power steering fluid and install it onto the rack bush.

Zoom Sized for Print

To prevent rack bush oil seal lip damage, wind vinyl tape around the rack end, and apply power steering fluid.
Install the rack bush onto the power steering rack.

Zoom Sized for Print

INSTALL CYLINDER END STOPPER
Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
Install a new wire into the cylinder end stopper.
Using a screwdriver, turn the cylinder end stopper counterclockwise by 450 ±50° .

Zoom Sized for Print

AIR TIGHTNESS TEST
Install SST onto the rack housing. SST 09631-12071 (09633-00010)
Apply vacuum of 53 kPa (400 mm Hg, 15.75 inch Hg) for about 30 seconds .
Check that there is no change in the vacuum. If there is a change in the vacuum, check the installation of the oil seals.

Zoom Sized for Print

INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
Coat a control valve upper bearing and a new control valve upper oil seal with power steering fluid.
Using SST and a press, install the control valve upper oil seal. SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320)

Zoom Sized for Print

Using SST and a press, install the control valve upper bearing. SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340)

Zoom Sized for Print

INSTALL POWER STEERING CONTROL VALVE
Expand 4 new control valve rings with your fingers.
NOTICE: Be careful not to over expand the control valve rings.

Coat the 4 control valve rings with power steering fluid.
Install the 4 control valve rings onto the control valve, and settle them down with your fingers.

Zoom Sized for Print

Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve. SST 09631-20081
NOTICE: Be careful not to damage the control valve rings.

Zoom Sized for Print

To prevent control valve upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
Coat the control valve upper oil seal lip with power steering fluid.
Install the control valve onto the control valve housing.
NOTICE: Be careful not to damage the control valve ring and control valve upper oil seal lip.

Coat a new oil seal lip with power steering fluid.

Zoom Sized for Print

Using SST and a press, install the oil seal. SST 09612-22011
NOTICE: Make sure that the oil seal is installed facing in the correct direction.

Apply grease to the needle roller bearing.
Install a new gasket onto the control valve housing.
Wind vinyl tape around the serrated part of the control valve.

Zoom Sized for Print

Install the control valve w/ control valve housing onto the rack housing with the 2 bolts. Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)

Zoom Sized for Print

Using SST, hold the control valve rotation and install a new lock nut. SST 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
Apply sealant to 2 or 3 threads of the rack housing cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

Zoom Sized for Print

Using a socket wrench (27 mm), install the rack housing cap. Torque: 59 Nm (597 kgf-cm, 43 ft. lbs.)

Zoom Sized for Print

Using a punch and a hammer, stake the rack housing cap and rack housing.
INSTALL RACK GUIDE
Install the rack guide.
Install the compression spring.
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
Temporarily install the rack guide spring cap.
ADJUST TOTAL PRELOAD
To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH steering rack ends sub-assy.

Zoom Sized for Print

Using SST, torque the rack guide spring cap. SST 09631-10021
Torque: 25 Nm (254 kgf-cm, 18 ft. lbs.)

Zoom Sized for Print

Using SST, loosen the rack guide spring cap. SST 09631-10021

Zoom Sized for Print

Using SST, turn the control valve to the right and left 1 or 2 times. SST 09616-00011
Using SST, loosen the rack guide spring cap until the compression spring is not functioning. SST 09631-10021

Zoom Sized for Print

Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification. SST 09616-00011, 09631-10021
Preload (turning): 1.2 to 1.5 Nm (12.2 to 15.3 kgf-cm, 10.6 to 13.3 inch lbs.)
Apply sealant to 2 or 3 threads of the rack guide spring cap nut. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Temporarily install the rack guide spring cap nut.

Zoom Sized for Print

Using SST, hold the rack guide spring cap and using another SST, torque the rack guide spring cap nut. SST 09616-00011, 09922-10010
Torque: 48 Nm (489 kgf-cm, 35 ft. lbs.)

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch) .
Precheck the total preload. Preload (turning): 1.2 to 1.5 Nm (12.2 to 15.3 kgf-cm, 10.6 to 13.3 inch lbs.)
Remove the RH and LH steering rack ends sub-assy.

Zoom Sized for Print

Apply MP grease to the control valve, as shown in the illustration.

Zoom Sized for Print

Wind vinyl tape around the serrated part of the control valve.
Install the dust cover onto the control valve housing.
INSTALL STEERING RACK END SUB-ASSY

Zoom Sized for Print

Install 2 new claw washers, and temporarily install the 2 steering rack end sub-assy.
HINT: Align the claws of the claw washer with the power steering rack grooves.

Using 2 SST, install the 2 rack end sub-assy. SST 09922-10010
Torque: 58.5 Nm (597 kgf-cm, 43 ft. lbs.)

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

HINT:
Using SST, hold the power steering rack and install the rack end sub-assy.
Use a torque wrench with a fulcrum length of 345 mm (13.58 inch)

Zoom Sized for Print

Using a brass bar and a hammer, stake the 2 claw washers.
NOTICE: Avoid any impact to the power steering rack.

Zoom Sized for Print

INSPECT STEERING RACK END SUB-ASSY
Ensure that the rack end sub-assy hole is not clogged with grease.
HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.

INSTALL STEERING RACK BOOT NO.2
INSTALL STEERING RACK BOOT NO.1

Zoom Sized for Print

INSTALL STEERING RACK BOOT NO.2 CLAMP
Using SST, tighten the rack boot No.2 clamp, as shown in the illustration. SST 09521-24010
Clearance: 3.0 mm (0.118 inch) or less

NOTICE: Be careful not to damage the rack boot No.2.

© 2017 ALLDATA LLC. All rights reserved. Terms and Conditions

wow thats a lot to take in. out of curiosity what are the "zoom sized for prints"

false