Stripped High Pressure Port on Steering Rack Control Valve Housing

[ClankBang]

So….

As the title states.

I replaced the rack with a new Toyota rack on my 01 about a year ago and when I did I noticed the high pressure line was leaking a bit.
I finally got around to replacing the lines this weekend. As I was torquing the high pressure line (my last step) the bolt suddenly loosened.
Damn!

The port is completely stripped.

So now I’m looking for advice.
The options as I see it

Buy a new rack (~$700)
Buy a reman rack (~$400) +( $250 core)
Buy a junk yard rack (~ $150) and swap the control valve housing. Anybody have an idea how difficult that would be?
Buy the reman rack and swap the housing then return the reman as the core.
Buy the control valve housing from Toyota (~$350)



I can also try to tap the port but I’m not sure the bolt will hold.

Helicoil? How would that do with a hydraulic fitting?

Machine shop? Can they save me?

 

[excessive]

Sorry that happened. A helicoil would probably work, but man that is a bad area for access. You'd probably have to pull the rack to do the work, and as i'm sure you already know, that is not a fun job.

 

[ClankBang]

Yes I figured from my research that I will be pulling the rack. I’m just not sure which way to go after that.
I have only run a tap a few times and have never place a heli coil (but that is what YouTube is for)

 

[2001LC]

03-07 Pinion housing below. Gives you and idea, of what you'll be drilling & tapping. Trick would be, to not damage the seat. Which takes certain type flat end drill bit & Tap. Machine shop would have bit & tap and can make perfectly square, which it must be square. They could likely do, without tearing down R&P. I'd have then use hydraulic thread sealer.

Swap with used pinion housing, would be my choice. But, then I've SST tools and used R&P on hand.
SST 32mm inverted socket here, to free pinion from it's housing.

This SST, holds the input shaft and is used to check preload with torque wrench.

 

[ClankBang]

Thank you for that info and pictures!

 

[excessive]

i shudder at thinking about doing the steering rack job. unfortunately one of the toughest jobs on the 100 series. Much easier if you have access to a lift

 

[2001LC]

Let me know direction you take, and if you need a housing.