This procedure covers the replacement of torn or damaged rack and pinion boots on a 2019-2024 Toyota RAV4 with 2.5L I4 engine and electric power steering.

Warnings

Tools required

Parts

• Rack and pinion boot kit (left) × 1 — Use OEM specification
• Rack and pinion boot kit (right) × 1 — Use OEM specification
• Cotter pins (tie rod end) × 2 — Use OEM specification
• Boot clamps (if not included in kit) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and secure on jack stands at manufacturer-approved lift points
5. Remove both front wheels completely
6. Turn steering wheel to gain access to boot clamps on each side (work one side at a time)

Procedure

1. 1

   Access tie rod end on first side
   Turn the steering wheel to position the tie rod end for easier access. Remove the cotter pin from the tie rod end castle nut using needle nose pliers. Discard the old cotter pin.
2. 2

   Separate tie rod end from knuckle
   Loosen but do not remove the tie rod end castle nut 2-3 turns to protect the threads. Use a tie rod end separator tool to separate the tie rod end from the steering knuckle. Once separated, remove the castle nut completely.
   ⚠Do not strike the tie rod end threads directly - keep the nut partially threaded to protect them
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
3. 3

   Remove outer boot clamps
   Locate the two clamps securing the outer rack boot (toward the wheel side). Use wire cutters or side cutters to cut and remove both the large and small boot clamps. Mark the position of the boot on the rack for reference during reassembly.
4. 4

   Remove inner boot clamps
   Cut and remove the clamps securing the inner side of the boot (toward the center of the rack). Slide the old boot off the rack assembly toward the outer tie rod. Inspect the rack surface for scoring or damage.
5. 5

   Clean rack surface
   Thoroughly clean the rack bar surface where the boot seals using brake cleaner and a clean rag. Remove all old grease, dirt, and debris. Inspect the rack bar for any damage, scoring, or corrosion that could tear the new boot.
   ℹ️Any damage to the rack surface may require rack replacement - boots will not seal properly on damaged surfaces
6. 6

   Install new boot with grease
   Apply a thin coat of lithium-based grease to the rack bar where the boot will seal. Slide the new boot onto the rack from the outer tie rod side, ensuring it is positioned correctly per your reference marks. Pack the boot interior with grease as specified in the boot kit instructions (typically 40-60 grams).
7. 7

   Secure boot clamps
   Install the new boot clamps (small clamp on inner side, large clamp on outer side) using boot clamp pliers or the appropriate clamp tool. Ensure clamps are positioned in the boot grooves and tightened securely. Verify the boot is not twisted and sits properly in its grooves.
8. 8

   Reconnect tie rod end
   Clean the tie rod end taper and steering knuckle bore. Insert the tie rod end stud into the knuckle and install the castle nut. Torque to specification, then advance the nut (if necessary) to the next castle slot to align with the cotter pin hole. Never back off the nut to align.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
9. 9

   Install new cotter pin
   Insert a new cotter pin through the castle nut and tie rod end stud. Bend the cotter pin ends outward to secure it properly. Ensure the cotter pin is fully seated and cannot work loose.
10. 10

    Repeat for opposite side
    Turn the steering wheel to access the opposite side. Repeat steps 1-9 for the other rack and pinion boot. Ensure both boots are properly installed and secured with no twists or improper seating.
11. 11

    Reinstall wheels
    Reinstall both front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground (wheels cannot spin). Torque lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Lower vehicle completely and remove jack stands
2. Perform final lug nut torque check after vehicle is on ground
3. Check steering wheel for proper center position
4. Wipe down any grease or debris from suspension components

Verification

• Start the engine and turn the steering wheel fully lock-to-lock several times while stationary
• Check both boots for proper seating and no leaking grease
• Verify all clamps are secure and boots are not twisted
• Test drive vehicle and verify normal steering operation with no unusual noises
• Re-inspect boots after test drive for any signs of grease leakage or improper installation
• Schedule an alignment check if tie rod positions were disturbed during removal

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