Power Steering Rack

This procedure covers the removal and installation of the electric power steering rack on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine and front-wheel drive.

Warnings

Tools required

Parts

• Electric power steering rack assembly × 1 — Use OEM specification
• Tie rod end cotter pins × 2 — Use OEM specification
• Steering rack mounting bolts × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and set parking brake
2. Turn steering wheel to center position and turn ignition off
3. Install steering wheel holder or locking device to prevent wheel rotation
4. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
5. Raise front of vehicle and support securely on jack stands placed on manufacturer-specified lift points
6. Remove both front wheels
7. Mark tie rod position on inner tie rod threads with center punch for approximate reinstallation reference

Procedure

1. 1

   Remove tie rod ends from steering knuckles
   Remove the cotter pins from both tie rod end castle nuts using needle nose pliers. Loosen but do not remove the tie rod end nuts. Using a tie rod separator tool, separate the tie rod ends from the steering knuckles. Remove the castle nuts and set tie rod ends aside.
2. 2

   Disconnect outer tie rod ends from inner tie rods
   Count and record the number of exposed threads on each inner tie rod before removal. Loosen the tie rod jam nuts. Unscrew the outer tie rod ends from the inner tie rods, counting rotations to maintain approximate toe setting. Remove tie rod ends completely.
3. 3

   Remove engine undercover and splash shields
   Remove all fasteners securing the engine undercover and front splash shields to access the steering rack. Remove and set aside covers.
4. 4

   Disconnect steering column intermediate shaft
   Locate the intermediate shaft connection at the steering rack input shaft. Mark the relationship between the upper and lower shafts for proper reassembly alignment. Remove the intermediate shaft lower pinch bolt. Carefully slide the intermediate shaft off the steering rack pinion splines using a pry bar if necessary. Support the shaft to prevent damage to the upper universal joint.
   ⚠Do not rotate the steering wheel or allow the intermediate shaft to separate at the upper joint, as this will disturb clockspring alignment.
5. 5

   Disconnect electrical connector from steering rack
   Locate the electric power steering motor connector on the passenger side of the steering rack. Press the locking tab and disconnect the electrical connector. Secure the connector away from the work area.
6. 6

   Remove steering rack mounting brackets
   Locate the two steering rack mounting brackets that secure the rack to the front subframe. Remove the mounting bracket bolts on both sides. Remove the brackets and set aside with hardware.
7. 7

   Support and remove steering rack
   Support the steering rack with one hand or have an assistant support it. Carefully maneuver the steering rack assembly toward the driver's side of the vehicle while angling to clear the subframe and other components. Remove the steering rack from the vehicle through the left wheel well opening. The rack must be rotated and tilted during removal to clear obstructions.
   ⚠The steering rack assembly is heavy and awkward. Use proper lifting technique and get assistance if needed.
8. 8

   Transfer components to new rack if necessary
   If the new steering rack does not come with inner tie rods or boots installed, transfer these components from the old rack. Ensure all dust boots are properly seated and boot clamps are secure. Apply grease to tie rod ball joints as specified.
9. 9

   Install new steering rack assembly
   Position the new steering rack assembly and carefully maneuver it into place through the driver's side wheel well opening, rotating and angling as needed to clear obstructions. Align the rack mounting points with the subframe. Ensure the rack is fully seated before installing mounting hardware.
10. 10

    Install steering rack mounting brackets
    Install both steering rack mounting brackets and hand-thread all bolts. Verify the rack is properly positioned and aligned. Tighten the mounting bolts to specification in an alternating pattern.
    ℹ️Verify tightening sequence with factory service manual if available, as some models require specific torque sequence.
11. 11

    Reconnect steering column intermediate shaft
    Verify the steering rack input shaft and intermediate shaft are both in the centered position. Align the marks made during disassembly. Slide the intermediate shaft onto the steering rack pinion splines, ensuring full engagement. Install the pinch bolt and tighten to specification.
    ⚠Misalignment of the intermediate shaft will cause incorrect steering wheel position and potential clockspring damage.
12. 12

    Reconnect electrical connector
    Connect the electric power steering motor electrical connector to the steering rack. Ensure the connector locks fully into place with an audible click.
13. 13

    Install outer tie rod ends
    Thread the outer tie rod ends onto the inner tie rods using the rotation count recorded during removal. Position the tie rod ends approximately to the punch marks made earlier. Tighten the jam nuts snug but do not fully torque yet, as alignment will need adjustment. Install the tie rod ends into the steering knuckles and install new castle nuts. Torque the castle nuts to specification. Install new cotter pins, advancing the nut slightly if necessary to align cotter pin holes.
    ℹ️Never loosen a castle nut to align cotter pin holes, only tighten.
14. 14

    Reinstall splash shields and undercover
    Reinstall all engine undercovers and splash shields removed during disassembly. Ensure all fasteners are properly secured.
15. 15

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until wheels contact the ground. Torque lug nuts to specification in a star pattern. Remove the steering wheel locking device. Reconnect the negative battery terminal.

Reassembly

1. Verify all electrical connections are secure and properly routed
2. Ensure all fasteners are tightened to specification
3. Double-check that all shields and covers are reinstalled
4. Confirm steering wheel is centered when front wheels are straight ahead

Verification

• Start the engine and verify no warning lights are illuminated on the instrument cluster
• Turn the steering wheel lock-to-lock while stationary and verify smooth operation with no binding or unusual noises
• Test drive the vehicle at low speed in a safe area and verify proper steering response and no pulling
• Check for any fluid leaks under the vehicle (there should be none as this is electric power steering)
• Schedule professional wheel alignment immediately, as toe settings will be incorrect and cause tire wear

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