On Aug. 25, I took my wifes 1999 Toyota 4 Runner to My Auto Import Center (Toyota dealership) because the power steering pressure hose was leaking. The estimate for replacing the complete power steering hose assembly was $520 installed. I knew it would be expensive because Toyota made both the pressure and return lines as one complete assembly, and it was very difficult to get at. The repairs were performed on time. The service manager mentioned that the mechanic had to loosen the rack and pinion unit and move it backwards to gain access to the hose connections. Fine - whatever it takes to get the job done right. I looked under the hood to make sure the hoses were installed and not leaking. All ok.
My wife got home and noticed a line of oil following her on the driveway. She looked under the vehicle and saw a puddle forming under the engine area. She called the Toyota garage and they told her to bring it right back - maybe something wasn't tightened, or give her a new estimate.
They put the vehicle on the hoist and noted that the power steering rack and pinion unit was leaking badly out of the right side, from the rubber boot. My wife correctly informed them that it wasn't leaking from there when the vehicle was brought in that morning. They made no mention of any other leaks or concerns after they replaced the hose assembly and I picked up the vehicle. They said it was a coincidence that it started leaking right after they worked on it. They tried to sell my wife a $1200 rack and pinion assembly, insallation included. She left and told me what happened.
When I got home from work that night I looked and saw that it was now leaking out of both the left and right sides of the rack and pinion books, more from the right, with oil puddles under both leaks.
I returned to My Auto Import Center the next day with the 4 Runner. I talked to the service manager, saying it was not a coincidence that I brought the vehicle in to get one leak fixed, and shortly afterwards it was leaking in two other places that weren't leaking before. I suggested that moving the rack and pinion assembly backwards without disconnecting the tie rods from the steering arms at the wheel assemblies might have put stress on the seals in the rack and pinion unit. He said that increased pressure from the new hose assembly probably caused the leaks, claiming that the seals were used to less pressure because the hose leak resulted in lower pressure in the rack and pinion unit.
I talked to his boss, and he said the same thing, adding that no way would they accept responsibility for causing the fluid leaks, and they wouldn't give me a break on repairing it.
I had the rack and pinion assembly replaced at an independent garage two days later for $500 installed. The mechanic said it would be highly unlikely that there would be higher pressure in the unit after replacing the hoses, and even if there was higher pressure, it wouldn't be more than what the system was designed to operate at. He couldn't definitely say that moving the rack and pinion unit backwards was the cause, but did say that it was possible. He added that he thought it was not simply a coincidence that two other power steering leaks could occur right after a separate leak was fixed.
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