DIY: Inner Tie Rod Replacement, with the Rack Gear Removed!
Here are a couple pictures and notes regarding replacement of the Inner Tie Rod Assembly where it screws on to the Rack Gear. The rack and pinion shown here is a remanufactured gear which came with new inner joints but they had substantial end play in them and needed replaced 5 years after installation. Hint: Not OEM parts!
If inspection of steering components gives results like this, inspect the inner and outer tie rods for free play.
Isolated free play to the inner tie rod sockets:
Link to Rack Removal:
DIY Rack and Pinion Removal/Install, Flush and Toe, Lots of PIC's!!!!
Remove the rack and pinion gear assembly. Following the measuring technique to preserve your sanity!
** Before removing the jamb nuts and tie rod ends, put the rack out on the ground and center it left to right by doing the following actions;
- with vise grips firmly grip the input shaft but try not to mar it.
- Turn input shaft to full left and stop.
- Turn right and count rotations tell it stops. Repeat to make certain and record #.
- Divide the full count in 1/2, record number (_________)
- Turn rack back left to full stop and then turn to the right the number turns recorded in the last step. Mine was 3 turns Lock to Lock so I turn it right 1.5 turns.
- Draw lines at these three areas using a square as a guide:
Left Jamb Nut:
Rack Mount:
Right Jamb Nut
** This represents the total toe and will be used to save you time setting the toe-in later. Having the RACK CENTERED IS A MUST! ** What you must understand is that if the rack gear was removed before at another point in time, someone MAY HAVE taken short cuts which COULD result in your steering wheel being crooked. Either way, This is the Correct thing to do and we'll fix a crooked steering wheel later!!
- Clean the outside to remove as much debris as possible to prevent it from getting inside the rack assembly.
Remove the outer tie rod ends, jamb nuts, and outer boot clamp:
- clean where the bellows boots attach to the rack. We don't want GRAVEL in the GEAR inside!
- remove only one boot at a time to prevent debris from getting in the other side. Usually this will mean cutting or spreading the clamp(s) to free the boot. Replace oil soaked boots, boots with tears, boots that are soft or have puncture holes.
- inspect the rack gear. If the boot is full of oil or the rack itself was leaking, had morning sickness, ect. . . you should replace the rack assembly.
Inner tie rod is ready for removal:
Here I used a chisel to bend the lock tab away from the inner socket.
Remove Inner Socket Assembly:
Tools; 24mm wrench for rack shaft and 1-5/16" crow foot on a 1/2" drive ratchet for the inner socket.
Clean the Tie Rod Threads and Vent Hole:
- confirm vent hole is open so the bellows can transfer air from side to side. Failure to clear these holes will result in blown up boots!
Add Red Loctite to threads:
Insert Lock Tab and Torque to spec:
Bend Lock Tabs over onto flats:
- be sure to use a backing weight of some kind so you don't hammer on the rack & pinion gear mesh. Support the shaft so you can bend the tab over on both flats. Use a vise directly on the socket if you have one.
When done bending the tabs, they should fit like this:
FWIW; this is the assembly lube from when the rack was put together and would be normal to find something like this under the bellows on the left side.
Removal of the left Inner T/R asm:
- yes, I found the correct wrench for the job here and layed down the cresent.
Preparation:
- Clean the shaft and boot before sealing in the debris.
- Install the boot and Clamps.
- Install the jamb nut.
- Install the tie rod end.
** Repeat process on the other side. ** Return to here when both sides are complete.
- Center the steering rack as done above; turn full left and stop. Turn right and count rotations tell it stops. Divide in 1/2, turn rack back to center.
Set Rack Gear back on marks and confirm body is correctly positioned on the mark!
- Adjust each jamb nut to the original position and snug down the outer tie rod end.
- Rough set the toe-in back to the original settings using the guide marks. Everything should align as it did the first time.
- try not to move the rack from center during installation into the car. Mark the shaft so you can tell if it moves! Snug the Jamb nuts to the tie rod ends so they don't move.
- Rack is ready to install!
Gotta Run, but Ill fix anything obvious later. . . (links ect) and post the How to remove Rack With Pix too! Next!
/randy
DIY: Inner Tie Rod Replacement, Rack Removed Lots of PiX!
Piece of Crap
I was schooled by the Camry! 
Good stuff buddy, nice and comprehensive!
Clean the Strainer in the Reservoir!
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