Toyota RAV4 2000-05

Removal & Installation

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Click image to see an enlarged view

Fig. Steering rack and related parts-2004

  1. Place the wheels in a straight-ahead position.
  2.  
  3. Remove the steering wheel pad.
  4.  
  5. Remove the steering wheel.
  6.  
  7. Remove the intermediate shaft from the gear.
  8.  
  9. Remove the steering column hole cover from the dash panel.
  10.  
  11. Disconnect the tie rod ends.
  12.  
  13. Disconnect the stabilizer bar.
  14.  
  15. Disconnect the pressure and return lines.
  16.  
  17. Remove the 2 gear mounting bolts.
  18.  
  19. Matchmark the intermediate shaft extension and control valve shaft.
  20.  
  21. Remove the intermediate shaft extension bolt and remove the gear.
  22.  

To install:

  1. Place the gear in position. Align the matchmarks and connect the intermediate extension shaft. Torque to 26 ft. lbs. (35 Nm).
  2.  
  3. Install the column cover plate and clamp.
  4.  
  5. Install the gear mounting bolts. Torque to 101 ft. lbs. (137 Nm).
  6.  
  7. Connect the pressure and return lines to the gear with the 2 bolts. Torque to 9 ft. lbs. (12.5 Nm).
  8.  
  9. Connect the pressure and return tube fittings. Torque to 29 ft. lbs. (40 Nm).
  10.  


NOTE
Use a torque wrench with a fulcrum length of 345mm. (13.58 inches).

  1. Connect the stabilizer bar. Torque to 22 ft. lbs. (29 Nm).
  2.  
  3. Connect the tie rods ends. Torque to 36 ft. lbs. (49 Nm).
  4.  
  5. Connect the intermediate shaft. Torque to 26 ft. lbs. (36 Nm).
  6.  
  7. Install the center spiral cable.
  8.  
  9. Install the power steering pump. Bleed the system.
  10.  
  11. Install the steering wheel. Make sure that everything is still in the straight-ahead position.
  12.  
  13. Torque the steering wheel nut to 37 ft. lbs. (50 Nm).
  14.  
  15. Install the pad.
  16.  
  17. Check the alignment.
  18.  



Click image to see an enlarged view

Fig. Rack and pinion exploded view-RAV4

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    To avoid personal injury when working on air bag equipped vehicles, work must be started after 90 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative battery terminal is disconnected. If the air bag system is disconnected with the ignition switch at the ON or ACC , diagnostic codes will be set. When removing the air bag, take care not to pull the air bag wiring harness. When carrying the wheel pad, carry it with the upper surface facing away. When storing it, keep the upper surface of the pad facing upward.

  4.  
  5. Turn the key to the LOCK position and lock the steering wheel in place.
  6.  
  7. Place a drain pan under the steering rack.
  8.  
  9. Remove or disconnect the following:

    Front wheels
     
    Right and left-hand engine undercovers
     
    Right and left-hand tie rod ends from the steering knuckle
     
    Front exhaust pipe
     
    Sway bar with the links
     

  10.  
  11. Disconnect the No. 2 intermediate shaft from the rack and pinion, as follows:
    1. Loosen the top bolt.
    2.  
    3. Remove the lower bolt holding the No. 2 intermediate shaft to the rack and pinion.
    4.  
    5. Shift the No. 2 intermediate shaft and place matchmarks on the control valve shaft and the No. 2 intermediate shaft.
    6.  
    7. Disconnect the No. 2 shaft from the rack and pinion.
    8.  

  12.  
  13. Install or connect the following:

    Pressure feed and return tubes from the rack and pinion, using a line wrench
     
    Pressure feed and return tube clamps, by removing the bolt
     
    Right and left lower control arms, from the steering knuckle
     

  14.  
  15. Remove the front suspension crossmember assembly, as follows:

    Both centermember set nuts, holding the centermember to the middle of the crossmember.
     
    Both rack and pinion assembly set bolts and nuts from the crossmember.
     
    Securely suspend the steering gear assembly.
     
    Support the suspension crossmember with a jack.
     
    Both bolts from the suspension crossmember
     
    Suspension crossmember with the lower suspension arms
     

  16.  
  17. Remove the rack and pinion.
  18.  

To install:

  1. Install or connect the following:

    Rack and pinion
     

  2.  
  3. Install the crossmember to the vehicle, as follows:

    Suspension crossmember with the lower control arms. Tighten both bolts to 152 ft. lbs. (206 Nm).
     
    Rack and pinion. Tighten the nuts/bolts to 83 ft. lbs. (113 Nm).
     
    Centermember to the crossmember. Tighten both set nuts to 82 ft. lbs. (112 Nm).
     

  4.  
  5. Install or connect the following:

    Right and left lower control arms
     
    Pressure feed and return tubes clamps
     
    Pressure feed and return tubes to the rack and pinion. Tighten the tubes to 26 ft. lbs. (36 Nm), using a torque wrench with a fulcrum length of 11.81 inches (300mm).
     
    Steering column No. 2 intermediate shaft to the rack and pinion. Align the marks and tighten the upper and lower pinch bolts to 26 ft. lbs. (35 Nm).
     
    Stabilizer bar links. Tighten the nuts to 22 ft. lbs. (29 Nm).
     
    Front exhaust pipe with new gaskets. Tighten the bolts to 35 ft. lbs. (48 Nm) and the nuts to 46 ft. lbs. (62 Nm).
     
    Right and left-hand tie rod ends to the steering knuckle. Tighten the nuts to 36 ft. lbs. (49 Nm) and install new cotter pins.
     
    Right and left-hand engine undercovers
     
    Front wheels
     

  6.  
  7. Fill the power steering unit and bleed the system. Check for leaks.
  8.  
  9. Check and/or adjust the front wheel alignment.
  10.  



Click image to see an enlarged view

Fig. Steering gear and related components-2000-2003

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    To avoid personal injury when working on air bag equipped vehicles, work must be started after 90 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative battery terminal is disconnected. If the air bag system is disconnected with the ignition switch at the ON or ACC , diagnostic codes will be set. When removing the air bag, take care not to pull the air bag wiring harness. When carrying the wheel pad, carry it with the upper surface facing away. When storing it, keep the upper surface of the pad facing upward.

  4.  
  5. Turn the key to the LOCK position and lock the steering wheel in place.
  6.  
  7. Place a drain pan under the steering rack.
  8.  
  9. Remove or disconnect the following:

    Front wheels
     
    Right and left side engine undercovers
     
    Right and left side tie rod ends from the steering knuckle
     
    Front exhaust pipe
     
    Sway bar with the links
     

  10.  
  11. Disconnect the No. 2 intermediate shaft from the rack and pinion, as follows:
    1. Loosen the top bolt.
    2.  
    3. Remove the lower bolt holding the No. 2 intermediate shaft to the rack and pinion.
    4.  
    5. Shift the No. 2 intermediate shaft and place matchmarks on the control valve shaft and the No. 2 intermediate shaft.
    6.  
    7. Disconnect the No. 2 shaft from the rack and pinion.
    8.  

  12.  
  13. Install or connect the following:

    Pressure feed and return tubes from the rack and pinion, using a line wrench
     
    Pressure feed and return tube clamps, by removing the bolt
     
    Right and left lower control arms, from the steering knuckle
     

  14.  
  15. Remove the front suspension crossmember assembly, as follows:

    Both centermember set nuts, holding the centermember to the middle of the crossmember.
     
    Both rack and pinion assembly set bolts and nuts from the crossmember.
     
    Securely suspend the steering gear assembly.
     
    Support the suspension crossmember with a jack.
     
    Both bolts from the suspension crossmember
     
    Suspension crossmember with the lower suspension arms
     

  16.  
  17. Remove the rack and pinion.
  18.  

To install:

  1. Install or connect the following:

    Rack and pinion
     

  2.  
  3. Install the crossmember to the vehicle, as follows:

    Suspension crossmember with the lower control arms. Tighten both bolts to 152 ft. lbs. (206 Nm).
     
    Rack and pinion. Tighten the nuts/bolts to 83 ft. lbs. (113 Nm).
     
    Centermember to the crossmember. Tighten both set nuts to 82 ft. lbs. (112 Nm).
     

  4.  
  5. Install or connect the following:

    Right and left lower control arms
     
    Pressure feed and return tubes clamps
     
    Pressure feed and return tubes to the rack and pinion. Tighten the tubes to 26 ft. lbs. (36 Nm), using a torque wrench with a fulcrum length of 11.81 inches (300mm).
     
    Steering column No. 2 intermediate shaft to the rack and pinion. Align the marks and tighten the upper and lower pinch bolts to 26 ft. lbs. (35 Nm).
     
    Stabilizer bar links. Tighten the nuts to 22 ft. lbs. (29 Nm).
     
    Front exhaust pipe with new gaskets. Tighten the bolts to 35 ft. lbs. (48 Nm) and the nuts to 46 ft. lbs. (62 Nm).
     
    Right and left side tie rod ends to the steering knuckle. Tighten the nuts to 36 ft. lbs. (49 Nm) and install new cotter pins.
     
    Right and left side engine undercovers
     
    Front wheels
     

  6.  
  7. Fill the power steering unit and bleed the system. Check for leaks.
  8.  
  9. Check and/or adjust the front wheel alignment.
  10.  



Click image to see an enlarged view

Fig. Steering gear and related components-2004-2005

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    Wait at least 90 seconds after disconnecting the negative battery cable before starting any repair work to prevent air bag and seat belt pretensioner activation.

  4.  
  5. Place the wheels in a straight-ahead position.
  6.  
  7. Remove the steering wheel pad.
  8.  
  9. Remove the steering wheel.
  10.  
  11. Remove the intermediate shaft from the gear.
  12.  
  13. Remove the steering column hole cover from the dash panel.
  14.  
  15. Disconnect the tie rod ends.
  16.  
  17. Disconnect the stabilizer bar.
  18.  
  19. Disconnect the pressure and return lines.
  20.  
  21. Remove the 2 gear mounting bolts.
  22.  
  23. Matchmark the intermediate shaft extension and control valve shaft.
  24.  
  25. Remove the intermediate shaft extension bolt and remove the gear.
  26.  

To install:

  1. Place the gear in position. Align the matchmarks and connect the intermediate extension shaft. Torque to 26 ft. lbs. (35 Nm).
  2.  
  3. Install the column cover plate and clamp.
  4.  
  5. Install the gear mounting bolts. Torque to 101 ft. lbs. (137 Nm).
  6.  
  7. Connect the pressure and return lines to the gear with the 2 bolts. Torque to 9 ft. lbs. (12.5 Nm).
  8.  
  9. Connect the pressure and return tube fittings. Torque to 29 ft. lbs. (40 Nm).
    NOTE
    Use a torque wrench with a fulcrum length of 345mm. (13.58 inches).

  10.  
  11. Connect the stabilizer bar. Torque to 22 ft. lbs. (29 Nm).
  12.  
  13. Connect the tie rods ends. Torque to 36 ft. lbs. (49 Nm).
  14.  
  15. Connect the intermediate shaft. Torque to 26 ft. lbs. (36 Nm).
  16.  
  17. Install the center spiral cable.
  18.  
  19. Install the power steering pump. Bleed the system.
  20.  
  21. Install the steering wheel. Make sure that everything is still in the straight-ahead position.
  22.  
  23. Torque the steering wheel nut to 37 ft. lbs. (50 Nm).
  24.  
  25. Install the pad.
  26.  
  27. Check the alignment.
  28.  

 
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