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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Right Side Steering Rack Bushing Removal (Continued)

16. Remove the cyl inder end stopper.

A. Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end
is visible through the service hole.
B. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise , and
remove the wire and the cylinder end stopper.
HINT
Use the hooked wire end or a 90 degree angle hooked pick to pull the end stopper out.
Fi gure 9.

2

Figure 10.

Wire

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Right Side Steering Rack Bushing Removal (Continued)

17. Remove the power steering rack bushing .

Figure 11 .

Plug the port while simultaneously turning the
input shaft counterclockwise.
HINT
The internal air pressure will cause the rack
bushing to get pushed out.

NOTICE
Do NOT turn the input shaft clockwise; it may
cause damage to the center seal on the rack
bar if it goes beyond its normal travel.

18. Remove the power steering rack bushing seal
and 0-ring .

Figure 12.

A. Using the SSTs listed below, remove the rack
bushing oil seal from the rack bushing .
SST: 09527-21011, Rear Axle Shaft Bearing
Remover (or equivalent)
SST: 09613-22011, Steering Rack Shaft
Bushing Puller

B. Using a small screwdriver or pick, remove the
0-ring from the rack bushing .
1

Rear Axle Shaft Bearing Remover

2

Steering Rack Shaft Bushing Puller

19. Thoroughly clean the accumulated debris from the steering rack bushing and the steering rack
housing before reassembly.

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Right Side Steering Rack Bushing Removal (Continued)

20. Install the power steering rack bushing seal.

Figure 13.

A. Coat the new rack bushing oil seal lip
and outside diameter surface with power
steering fluid .
B. Using the SSTs listed below and a press,
install the rack bushing oil seal to the
rack bushing .
SST: 09950-60010-01, Replacer Set #1
(09951-00400-01, Replacer 40)
SST: 09950-70010-01, Handle Set
(09951-07100-01, Handle Assembly 100 -

4.25")

C. Coat a new 0-ring with power steering fluid
and install it to the rack bushing .
21. Inspect and clean the inside of the rack housing .

1

Replacer 40, Handle Assembly 100 - 4.25"

2

Oil Seal

Figure 14.

Look down inside the rack housing to confirm it is
clean before reinstalling the rack bushing .

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Right Side Steering Rack Bushing Removal (Continued)

22. Install the power steering rack bushing to the
rack housing .

Figure 15.

A. Wrap vinyl tape around the end of the steering
rack in order to prevent damaging the rack
bushing oil seal.

B. Coat the rack bushing oil seal lip, vinyl tape ,
and the 0-ring with power steering fluid .
C. Install the rack bushing to the rack housing .

1

23 . Install the cylinder end stopper.

I

Vinyl Tape

Figure 16.

A. Align the installation hole for the wire of the
cylinder end stopper with the slot of the
rack housing .
B. Install a new wire into the cylinder end stopper.
C. Using a screwdriver, turn the cylinder end
stopper counterclockwise by 450° +/-50°.

2

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure (Continued)
Vacuum Air Test of Power Steering Rack System

1. Coat the Test Tool 0-ring with power steering
fluid and pre-install the 0-ring onto the tester
as shown .
SST: 09633-00010-01, Test Tool 0-ring

Figure 17.

HINT
Pre-installing the 0-ring will help ensure proper
positioning and therefore ensure complete

sealing between the two surfaces.

2. Install the following SSTs to the rack housing .
SST: 09631-12071, Steering Rack Oil Seal Test Tool
SST: 09633-00010-01, Test Tool 0-ring (2)

1

Vacuum Pressure Tester

2

0-ring

Figure 18.

NOTICE
Be sure NOT to over-torque the SST as it can
crush the opening of the seal shut and cause
a false reading.

Steering Rack Oil Seal Test Tool, 0-ring

3. Apply a vacuum of 53 kPa for about 30 seconds.
Vacuum Pressure: 53 kPa (400 mmHg, 15.75 in.Hg)

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Vacuum Air Test of Power Steering Rack System (Continued)

4. Check that there is no change in the vacuum . If there is a change in the vacuum , check the
installation of the 0-rings .
5. Remove the 2 0-rings when the SST is removed from the steering rack housing .

Power Steering Rack End Sub-assembly Installation

1. Install the steering rack end sub-assembly.

A. Install the new claw washers , and temporarily install the rack end sub-assembly.
HINT
Align the claws of the claw washer with the steering rack grooves.

B. Using the Variable Open Wrench SST, install
the rack end sub-assembly.

Figure 19.
~---------------~

SST: 09922-10010-01, Variable Open Wrench
Torque: 58.5 N*m (597 kgf*cm, 43 ft*lbf)
NOTICE
Use SST 09922-10010-01 (Variable Open
Wrench) following the direction shown
in the illustration. Failure to follow this
procedure will result in the tie rod not being
tightened to the proper torque.

HINT
• Using the Variable Open Wrench SST,
hold the rack and install the rack end
sub-assembly.
Use a torque wrench with a fulcrum
length of 345 mm (13.58 in.).

1

LH

2

RH

3

Variable Open Wrench

4

Fulcrum Length

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Power Steering Rack End Sub-assembly Installation (Continued)

2. Use a brass bar and a hammer to stake the
claw washer.

Fi gure 20.

NOTICE
Clamp the tie rod as shown to help avoid any
impact to the steering rack.

3. Inspect the power steering rack end .
Ensure that the holes of the rack ends are NOT
clogged with grease.

Figure 21 .

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

4. Install the steering rack boot.

Figure 22.

A. Apply a small coat of silicone grease to the
inside clamping surface of the small end of
the boot as shown .
B. Install the steering rack boot.
C. Install the steering rack boot clip using pliers .

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Power Steering Rack End Sub-assembly Installation (Continued)

5. Install the steering rack boot clamp.

Figure 23.

Using the SST, tighten the rack boot clamp as
shown in the illustration.
SST: 09521-24010, Drive Shaft Boot
Clamping Tool (or equivalent)
Clearance: 3.0 mm (0.18 in.) or less

1

Drive Shaft Boot Clamping Tool

2

Clearance: 3.0 mm (0.18 in.) or Less

6. Install the steering rack boot clip using pliers.
7. Install the tie rod assembly.

Figure 24.

Screw the lock nut and tie rod assembly on the
rack end until the matchmarks are aligned .
Torque: 74 N*m (755 kgf*cm, 55 ft*lbf)

1

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Matchmarks

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Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure
Power Steering Rack End Sub-assembly Installation (Continued)

8. Install the steering left turn pressure tube .

Figure 25.

A. Coat 2 NEW 0-rings with power steering fluid

and install them to the left turn pressure tube.
B. Using a 12 mm union nut wrench
(or equivalent) , install the left turn pressure
tube to the steering link assembly.
Torque: 12 N*m (117 kgf*cm, 8 ft*lbf)
HINT
Use a torque wrench with a fulcrum length
of 250 mm (9.84 in.).
1

0-ring

2

Union Nut Wrench , 12 mm (or equivalent)

3

Fulcrum Length

9. Install the steering right turn pressure tube.
A. Coat 2 NEW 0-rings with power steering fluid and install them to the right turn pressure tube.

B. Using a 12 mm union nut wrench (or equivalent) , install the right turn pressure tube to the
steering link assembly.
Torque: 12 N*m (117 kgf*cm, 8 ft*lbf)
HINT
Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

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Page 18 of 18

Power Steering Rack Leak from Right Side: Overhaul Procedure

Repair Procedure (Continued)
Power Steering Rack Installation

Reinstall the power steering rack.
Refer to TIS , applicable model and model year Repair Manual:
• 2004 I 2005 Sienna :
Steering - Power Assist Systems - "Rack & Pinion Power Steering Gear Assy: Overhaul"
• 2006 I 2007 I 2008 I 2009 Sienna :
Steering - Power Assist Systems - "Power Steering: Rack & Pinion Power Steering Gear:
Reassembly"
• 2010 Sienna :
Steering - Power Assist Systems - "Power Steering: Steering Gear: Reassembly"

Repair Confirmation

1. Confirm there is NO power steering leak by turning the steering wheel left and right with the
engine running .
2. Test drive the vehicle and verify that the steering wheel is centered and NO other alignment
or vehicle handling concerns are observed.

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