So the other week I noticed a good 5mm of play in my LH steering rack end(ball joint on rack end of tie rod).
Now this is a ridiculous amount of movement to have in that ball joint especially because I've only done 40k since new. I have a 4in lift and 33's along with a heap of other accessories but these mods should not have any effect on this part of the steering. If anything were to go I would think first would be steering pump or rack seals. Also having the Ultimate Smart Lift, the kit comes with rack spacers along with other unique components to keep the steering geometry at stock angles.
My power steering fluid was black as hell so I did a complete system flush, putting a system treatment fluid along with about 10 liters of new fluid through to completely clean out the whole power steering system. Also added some conditioner on the final fill.
After doing this I proceeded to replace the rack end, which is a heavier duty lengthened rod from Ultimate Suspension.
What I found was like nothing I've ever seen on any other vehicle I've ever worked on. The LH rack boot was completely full of dirty rusty water. About 300ml came out I reckon. The ball joint had rusted out that bad it had over 5mm of end play in it and the steering rack itself was covered in thick chunky rust that's really pitting into the hardened steel of the rack. Somehow the rack seals don't seem to be damaged yet and have not leaked. I cleaned it all up as best as possible with steel wool and emery paper, replaced the rack end and refit the boot. I then checked the RH side. The rack end is ok but there is also some rusty water in the boot too. The rack seems to have little rust there but the oil is starting to leak and the boot has a very tiny hole in it, the LH side boot had no visible holes.
It's been about 3 weeks since then and already the power steering fluid is going brown and smelling a little burnt. There is also water condensation in top of reservoir with that milky consistency you get when water and oil mix.
I will be going to Toyota soon and hoping for a new rack under warranty but will be expecting to hear them object due to lift, tires etc.
I'm not going to let them get away with that though if it's the case, there's no way any of my modifications could cause rack boots to fill with water and rust the shit out of the rack. In 12 years of being a mechanic I've never seen anything like it.
Anyone else had such a serious and f$&cked up issue with their steering rack?