T-SB-0030-14

April 17, 2014
T-SB-0030-14
Power Steering Rack Leak from Right Side: Overhaul
Procedure
Service
Category
Steering
Section
Steering Gear/Linkage
Market
USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2004 – 2010
Sienna
Drive Type(s): 4WD, 2WD
Engine(s): 3MZ, 2GR
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0097-12.
• The entire bulletin has been updated to include Power Steering Rack Gasket overhaul.
Service Bulletin No. T-SB-0097-12 is Obsolete and any printed versions should be discarded.
Be sure to review the entire content of this bulletin before proceeding.
Introduction
A new repair procedure and overhaul kit have been developed for repairing the power steering
rack to improve the overall serviceability and reduce ownership cost. This repair procedure only
applies to vehicles where the steering rack leak is originating from the right (passenger) side and
is the OEM steering rack assembly.
NOTE
• This bulletin does NOT apply to aftermarket or rebuilt steering rack assemblies.
• The procedure in this bulletin is only one of several repair options which include, but are not
limited to, complete steering rack overhaul and steering gear replacement. Please use your
best judgment to recommend the most effective repair method for the customer.
Parts Information
PART NUMBER
PART NAME
QTY
04003-38208
Power Steering Rack Gasket Kit
1
95381-03020
Cotter Pin
2
© 2014 Toyota Motor Sales, USA
Page 1 of 18
April 17, 2014
T-SB-0030-14
Page 2 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
ST1401
R & R Steering Gear Assembly and Overhaul
Right (Passenger) Side Power Steering Rack
2.8
44250-08030
44250-08040
65
13
APPLICABLE WARRANTY
• This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
• Warranty application is limited to occurrence of the specified condition described in this
bulletin.
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Ball Joint Puller*
09628-62011-01
1
Rack & Pinion Holding Tool*
09612-00012-01
1
Variable Open Wrench*
09922-10010-01
2
Steering Socket*
09616-00010-02 / 09616-00011
1
Steering Rack Shaft Bushing Puller*
09613-22011
1
Steering Rack Oil Seal Test Tool*
09631-12071
1
Test Tool O-Ring*
09633-00010-01
2
Rear Axle Shaft Bearing Remover (or equivalent)
09527-21011
1
Drive Shaft Boot Clamping Tool (or equivalent)
09521-24010
1
Replacer Set #1*
(Replacer 40)
09950-60010-01
(09951-00400-01)
1
Handle Set*
(Handle Assembly 100 – 4.25”)
09950-70010-01
(09951-07100-01)
1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 3 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Required Tools & Equipment (Continued)
REQUIRED TOOLS & MATERIAL
QUANTITY
Hand Vacuum Pump w/ Gauge
1
Soft Jaw Attachment (Bench Vise)
1
Union Nut Wrench, 17 mm (or equivalent)
1
Union Nut Wrench, 12 mm (or equivalent)
1
Power Steering Fluid (Dexron II, III, or equivalent)
As Needed
Silicone Grease
As Needed
Overview
1. Confirm origin of oil leak.
2. Remove the power steering rack.
3. Thoroughly clean and inspect the power steering rack.
4. Remove the right side steering rack bushing assembly and install new O-ring and seal.
5. Vacuum air test the power steering rack to confirm repair.
6. Reinstall the power steering rack to the vehicle.
7. Confirm by test driving and checking for leaks.
Repair Procedure
Confirmation of Steering Rack Oil Leak Source
Place the vehicle on the lift to confirm that only the right side steering rack boot is leaking.
Is the leak from the right side of the rack only?
• YES — Proceed with this bulletin.
• NO — Steering rack is leaking from the left side, both sides, or another location. STOP.
This bulletin does NOT apply. Order the complete Power Steering Rack Gasket Kit and rebuild
the steering rack assembly using the procedure outlined in the applicable Repair Manual.
NOTE
This bulletin does NOT apply to aftermarket or rebuilt steering rack assemblies.
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 4 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Power Steering Rack Removal
Remove the power steering rack assembly.
Refer to the Technical Information System (TIS), applicable model and model year Repair Manual:
• 2004 / 2005 Sienna:
Steering – Power Assist Systems – “Rack & Pinion Power Steering Gear Assy: Overhaul”
• 2006 / 2007 / 2008 / 2009 Sienna:
Steering – Power Assist Systems – “Power Steering: Rack and Pinion Power Steering Gear:
Disassembly”
• 2010 Sienna:
Steering – Power Assist Systems – “Power Steering: Steering Gear: Disassembly”
Power Steering Rack Cleaning & Inspection
Clean power steering rack and inspect for defects.
• If the steering rack housing is damaged, repair the damaged or worn parts as necessary.
• If replacement parts are NOT available or cannot restore the housing integrity/operability,
do NOT proceed with this bulletin.
• Replace steering rack housing if damaged.
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 5 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Right Side Steering Rack Bushing Removal
1. Prepare the steering rack by steering the rack to the left-hand lock (clockwise).
2. Remove the steering left turn pressure tube.
Figure 1.
.
A. Remove the tube clamp from the turn
pressure tubes.
1
B. Using a 12 mm union nut wrench
(or equivalent), disconnect the left turn
pressure tube.
C. Remove the 2 O-rings from the left turn
pressure tube and discard.
2
1
Union Nut Wrench, 12 mm (or equivalent)
2
O-ring
3. Remove the steering right turn pressure tube.
A. Disconnect the right turn pressure tube using the procedure above.
B. Remove the 2 O-rings from the right turn pressure tube and discard.
Figure 2.
HINT
Wrap the steering rack in cloth or shop
rags to capture any excess power
steering fluid that will leak during
the repair.
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 6 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Right Side Steering Rack Bushing Removal (Continued)
4. Using the Rack & Pinion Holding Tool SST, secure
the steering link assembly to prevent damage.
Figure 3.
.
SST: 09612-00012-01, Rack & Pinion Holding Tool
1
NOTICE
Wrap the SST with tape before use, in order to
prevent damaging the steering link assembly.
1
5. Put matchmarks on the tie rod assembly and the
rack end.
Rack & Pinion Holding Tool
Figure 4.
.
1
1
Matchmarks
6. Loosen the lock nut and remove the tie rod assembly RH and the lock nut.
7. Remove the tie rod assembly RH.
8. Remove the 2 RH steering rack boot clips.
9. Using pliers, remove the steering rack boot No. 2 clamp.
10. Remove the steering rack boot No. 1 clamp.
11. Remove the steering rack boot No. 2.
12. Remove the steering rack boot No. 1.
© 2014 Toyota Motor Sales, USA
T-SB-0030-14
April 17, 2014
Page 7 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Right Side Steering Rack Bushing Removal (Continued)
13. Remove the steering rack end sub-assembly.
A. Using soft jaws, clamp the steering rack end
as shown.
Figure 5.
1
NOTICE
This step is necessary to avoid
transmitting impact to the steering rack
gear and steering pinion gear which
may cause damage.
1
Claw Washer
B. Using a screwdriver and a hammer, unstake the claw washer.
C. Using the Variable Open Wrench SST, remove
the right-hand rack end and the claw washer.
Figure 6.
SST: 09922-10010-01, Variable Open Wrench
1
1
© 2014 Toyota Motor Sales, USA
Variable Open Wrench
T-SB-0030-14
April 17, 2014
Page 8 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Right Side Steering Rack Bushing Removal (Continued)
14. Inspect the left-hand and right-hand tie rod ends
for excessive wear and play. Push and pull the tie
rod to confirm condition. Replace as necessary.
Figure 7.
.
15. Thoroughly clean the steering rack assembly.
Figure 8.
.
NOTICE
Be sure to clean the inside of the rack assembly
to prevent foreign material from damaging the
rack surface (for example, when boot has torn
and allowed debris to collect around the inside
of the rack).
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 9 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Right Side Steering Rack Bushing Removal (Continued)
16. Remove the cylinder 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.
Figure 9.
Figure 10.
1
2
1
Cylinder End Stopper
2
Wire
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 10 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Right Side Steering Rack Bushing Removal (Continued)
17. Remove the power steering rack bushing.
Figure 11.
.
Figure 12.
.
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 O-ring.
2
A. Using the SSTs listed below, remove the rack
bushing oil seal from the rack bushing.
1
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
O-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.
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 11 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
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.
1
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 O-ring with power steering fluid
and install it to the rack bushing.
21. Inspect and clean the inside of the rack housing.
2
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.
© 2014 Toyota Motor Sales, USA
.
April 17, 2014
T-SB-0030-14
Page 12 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
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 O-ring with power steering fluid.
1
C. Install the rack bushing to the rack housing.
23. Install the cylinder end stopper.
2
1
Vinyl Tape
2
Rack Bushing
Figure 16.
.
A. Align the installation hole for the wire of the
cylinder end stopper with the slot of the
rack housing.
2
B. Install a new wire into the cylinder end stopper.
C. Using a screwdriver, turn the cylinder end
stopper counterclockwise by 450◦ +/–50◦.
1
1
Cylinder End Stopper
2
Wire
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 13 of 18
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 O-ring with power steering
fluid and pre-install the O-ring onto the tester
as shown.
Figure 17.
.
SST: 09633-00010-01, Test Tool O-ring
HINT
Pre-installing the O-ring will help ensure proper
positioning and therefore ensure complete
sealing between the two surfaces.
1
2
2. Install the following SSTs to the rack housing.
1
Vacuum Pressure Tester
2
O-ring
Figure 18.
.
SST: 09631-12071, Steering Rack Oil Seal Test Tool
SST: 09633-00010-01, Test Tool O-ring (2)
NOTICE
1
Be sure NOT to over-torque the SST as it can
crush the opening of the seal shut and cause
a false reading.
1
3. Apply a vacuum of 53 kPa for about 30 seconds.
Vacuum Pressure: 53 kPa (400 mmHg, 15.75 in.Hg)
© 2014 Toyota Motor Sales, USA
Steering Rack Oil Seal Test Tool, O-ring
April 17, 2014
T-SB-0030-14
Page 14 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
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 O-rings.
5. Remove the 2 O-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.
1
SST: 09922-10010-01, Variable Open Wrench
Torque: 58.5 N*m (597 kgf*cm, 43 ft*lbf)
3
NOTICE
4
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
2
3
• 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.).
4
1
LH
2
RH
3
Variable Open Wrench
4
Fulcrum Length
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 15 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Power Steering Rack End Sub-assembly Installation (Continued)
2. Use a brass bar and a hammer to stake the
claw washer.
Figure 20.
.
Figure 21.
.
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.
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.
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
Page 16 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
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.
1
SST: 09521-24010, Drive Shaft Boot
Clamping Tool (or equivalent)
Clearance: 3.0 mm (0.18 in.) or less
2
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
1
© 2014 Toyota Motor Sales, USA
Matchmarks
April 17, 2014
T-SB-0030-14
Page 17 of 18
Power Steering Rack Leak from Right Side: Overhaul Procedure
Repair Procedure (Continued)
Power Steering Rack End Sub-assembly Installation (Continued)
8. Install the steering left turn pressure tube.
Figure 25.
.
A. Coat 2 NEW O-rings with power steering fluid
and install them to the left turn pressure tube.
3
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)
1
HINT
2
Use a torque wrench with a fulcrum length
of 250 mm (9.84 in.).
1
O-ring
2
Union Nut Wrench, 12 mm (or equivalent)
3
Fulcrum Length
9. Install the steering right turn pressure tube.
A. Coat 2 NEW O-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.).
© 2014 Toyota Motor Sales, USA
April 17, 2014
T-SB-0030-14
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 / 2005 Sienna:
Steering – Power Assist Systems – “Rack & Pinion Power Steering Gear Assy: Overhaul”
• 2006 / 2007 / 2008 / 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.
© 2014 Toyota Motor Sales, USA