This procedure covers removal and replacement of the electric power steering gear box (rack and pinion assembly) on a 2019-2024 Toyota RAV4 with 2.5L I4 engine and front-wheel drive.

Warnings

Tools required

Parts

• Electric power steering rack assembly × 1 — Use OEM specification
• Steering shaft intermediate shaft roll pin × 1 — Use OEM specification
• Tie rod end cotter pins × 2 — Use OEM specification
• Rack mounting hardware kit (if not included with rack) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position and verify front wheels are pointing straight ahead
4. Lock steering wheel in center position using steering wheel lock or secure with seatbelt
5. Disconnect negative battery cable and wait 90 seconds for airbag system to discharge
6. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
7. Remove both front wheels
8. Mark tie rod end position on tie rod threads with paint or marker for approximate reinstallation reference
9. Photograph or document tie rod adjustment for reference

Procedure

1. 1

   Disconnect steering shaft
   From inside vehicle, locate steering shaft intermediate coupling at base of steering column under dash. Remove access panel if present. Mark alignment of upper and lower shaft yokes for reassembly. Remove roll pin securing intermediate shaft to steering rack pinion shaft using punch and hammer. Carefully drive roll pin completely out and retain for comparison with replacement pin. Separate intermediate shaft from rack pinion shaft by pulling upward on shaft.
2. 2

   Remove front tie rod ends
   Remove cotter pins from both tie rod end castle nuts and discard. Loosen but do not remove tie rod end castle nuts. Use ball joint separator to break taper connection between tie rod ends and steering knuckles. Remove castle nuts completely and separate tie rod ends from knuckles. Allow tie rod ends to hang freely.
   ⚠Keep tie rod end castle nuts partially threaded during separation to prevent sudden release and potential injury.
3. 3

   Disconnect electrical connector
   Locate electric power steering motor on steering rack assembly. Press release tab and disconnect electrical connector from EPS motor. Secure connector away from work area to prevent damage.
4. 4

   Remove steering rack mounting brackets
   Locate two steering rack mounting brackets that secure rack to subframe/crossmember. These brackets are typically positioned on either side of rack housing. Remove mounting bracket bolts and remove brackets. Inspect bracket bushings and replace if worn or damaged.
   ⚠Support steering rack with transmission jack or helper before removing final mounting bolts as rack is heavy and may drop suddenly.
   Torque spec

   Rack Bolts102 Nm (75 lb-ft)
5. 5

   Remove steering rack assembly
   With rack mounting brackets removed, carefully guide steering rack assembly toward driver side of vehicle through subframe opening. Maneuver rack boots and tie rod ends through suspension components. It may be necessary to rotate rack and angle tie rod ends to clear lower control arms and other components. Remove rack completely from vehicle and place on clean workbench.
   ℹ️If rack does not have sufficient clearance for removal, verify all mounting hardware is removed and consult service manual for potential need to lower subframe for additional clearance.
6. 6

   Transfer tie rod ends to new rack
   Count and record number of exposed threads on old rack between tie rod end and rack housing lock nut. Loosen lock nuts on old rack and unthread tie rod ends, counting full rotations. Clean tie rod threads with wire brush. Thread tie rod ends onto new rack assembly to same thread count/position as documented from old rack. Do not fully tighten lock nuts yet as final adjustment will occur during alignment.
   ℹ️This step provides approximate toe setting only. Professional alignment is still required but will reduce initial toe misalignment.
7. 7

   Install new steering rack
   Guide new steering rack assembly into vehicle from driver side, maneuvering through subframe opening. Route tie rod ends through suspension components. Position rack so pinion shaft protrudes through firewall opening and rack mounting points align with subframe mounting locations. Ensure rack boots are not twisted or damaged during installation.
8. 8

   Install mounting brackets
   Install steering rack mounting brackets over rack housing and align with subframe bolt holes. Install mounting bracket bolts and tighten to specification following sequence specified in service manual if provided. Ensure rack is centered in vehicle and both rack boots have equal extension on each side before final tightening.
   Torque spec

   Rack Bolts102 Nm (75 lb-ft)
9. 9

   Reconnect electrical connector
   Connect electrical connector to electric power steering motor. Ensure connector locks securely with audible click. Verify connector locking tab is fully engaged.
10. 10

    Connect tie rod ends to knuckles
    Position tie rod ends into steering knuckle tapers. Install new castle nuts and tighten to specification. Ensure cotter pin holes in castle nuts align with holes in tie rod studs. If alignment is off, tighten castle nut additional amount (do not loosen) until next slot aligns. Install new cotter pins and bend ends to secure.
    ⚠Never loosen castle nut to align cotter pin hole. Only tighten to next alignment position.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
11. 11

    Reconnect steering shaft
    Verify steering wheel is still locked in center position. Align steering rack pinion shaft splines with intermediate steering shaft splines, matching alignment marks made during disassembly. Slide intermediate shaft onto pinion shaft ensuring full engagement. Align roll pin holes in shaft coupling. Install new roll pin and drive fully into place using punch and hammer until pin is flush on both sides of coupling.
    ⚠️Misalignment of steering shaft can cause steering wheel to be off-center and may damage clockspring. Verify proper alignment before installing roll pin.
12. 12

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten lug nuts in star pattern. Lower vehicle until wheels contact ground but vehicle weight is not fully transferred. Torque lug nuts to specification in star pattern. Lower vehicle completely and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Reconnect battery and initialize system
    Reconnect negative battery cable. Turn ignition to ON position without starting engine. Turn steering wheel slowly lock-to-lock 2-3 times to allow EPS system to initialize and calibrate. Check instrument cluster for any warning lights related to power steering or steering angle sensor.

Reassembly

1. Reinstall any dash panels or covers removed for steering shaft access
2. Verify all electrical connectors are secure and no tools or parts remain in work area
3. Tighten tie rod end lock nuts after professional alignment is completed

Verification

• Start engine and verify no power steering warning lights are illuminated on instrument cluster
• Turn steering wheel lock-to-lock while stationary and verify smooth operation with no binding, clicking, or unusual noises
• Test drive vehicle at low speed in safe area and verify steering response is normal and wheel returns to center properly
• Verify steering wheel is centered when driving straight
• Have vehicle professionally aligned immediately - check and adjust front toe, camber, and caster as needed
• After alignment, verify steering wheel is centered and vehicle tracks straight with no pull
• Re-check all torque specifications after test drive, especially tie rod end castle nuts and rack mounting bolts

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