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Old 09-23-2022, 06:31 AM   #1
IndestructibleYaris
 
Drives: 2007 Toyota Yaris Sedan
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Rack and Pinion Rebuild Tool

I'm getting into rebuilding rack and pinions for cars, yet the yaris is the only design that's never supposed to be serviced. What gives? What do you do when it inevitably wears out? The tool to remove the preload cap is some weird torx shaped bit the size of a golfball. Have mercy. I tried a piece of 1/8" thick flat stock and it just pretzels. The cap must be loctited on there, but it's not something that's meant to be torched. Any help is appreciated. Thanks

By the way, this is the first fastener in my automotive and big rig career to not come loose
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Old 09-23-2022, 08:29 AM   #2
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Itís possible that by the time the rack wears out itís time for a new car.

Well I donít even know what youíre talking about the part I mean kind of but donít give up!
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Old 09-24-2022, 08:51 AM   #3
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I am just guessing the year is 2007 from the profile but from what I am seeing in the manual which I could be wrong is a 19mm Allen/hexagon wrench and it does say that use LOCTITE 242 (blue/medium strength) or equivalent so you are right it is indeed Loctited in. If you are rebuilding it I'd say whatever and put some heat into it just to soften the Loctite but other than that long breaker bar and a vise or put it back on the car try to get it off with shear strength. Only other thing I could think of without heat is just stick an impact on it till it comes loose.
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Old 09-24-2022, 09:35 AM   #4
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Arrow

This is a picture from the service manual for my 2001 echo. Is this the same as the yaris eand if so what is the part youíre talking about
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Old 09-24-2022, 12:25 PM   #5
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Old 09-24-2022, 12:28 PM   #6
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Perhaps a square or hex shaped bOlt Will fit the 12 point cavity. You could possibly make a tool from that
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Old 09-24-2022, 12:50 PM   #7
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Thanks wee, it is 12 point so a bolt head could make a tool, but that thing is in there. I might as well just air hammer it after applying heat. It is ridiculously tight, or the loctite is doing its job. One of the things about the second gen yaris is it is an electronic assist steering, no power steering lines to worry about, but that rack preload nut should be able to be adjusted to loosen or tighten the rack, which can loosen or tighten the steering depending on how far you go. After hitting a curb mine is rather tight and this is the only design I've ever seen where the fastener is so conveluded
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Old 09-24-2022, 03:23 PM   #8
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You said you can’t heat it up very much. Why is that? As far as I can see if it was mine it would be heated as much as I needed to
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Old 09-24-2022, 03:38 PM   #9
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if WeeYari pic is correct that is called Triple square they are also used as the head bolts now I can not tell you what size that is without measurements but that is a triple square.
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Old 09-26-2022, 04:51 PM   #10
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Did you ever get the 12 point part out of the rack? If so how?

Thanks!
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Old 11-10-2022, 02:17 AM   #11
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Quote:
Originally Posted by bronsin View Post
Did you ever get the 12 point part out of the rack? If so how?

Thanks!
I would need to remove the rack, the space is too tight for any work. It might happen eventually but not for a while. The plug is too tight and needs an air hammer. It can't be heated, or at least it shouldn't, in case the rack bushing material that preloads the center, right behind the cap, might be made of plastic. They sometimes are, or they're metal. I have a feeling this rack is adjustable, it has to be, because otherwise they'd never be able to be assembled because the tolerances would result in unusable racks going out of the factory. To be continued
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