2000 T4R 4WD Steering Rack, Lines, Pump and Resevoir issues

Hey all, a couple months ago the steering rack on my 2000 T4R 4WD started leaking from the seal where the steering column goes into the top. Too big of a job for me so I dropped it off at a reputable local shop. They have had my truck for 10 days and are having serious issues (they've been in business 23 years and have never seen anything like this). FYI, my steering was perfect before dropping it off, only the leak (i.e. could turn the wheel with my index finger, truck would recenter after a turn, etc. I have owned this truck since I bought it NEW in December 2000; 282k miles; Everything is stock... no mods)

The issue is after installing everything, when driving, the steering remains tight and will not return to center after a turn or even after a lane change at highway speeds. You literally have to turn the wheel to get it to go where you want (if that makes sense). The wheels "should" mostly come into alignment on their own especially after turning a street corner.
Here's everything that has been done:

4 different racks from 3 different vendors (not OEM)
3 different pumps from 2 different vendors (not OEM)
New lines (not OEM)
Refurbished Reservoir (my original but totally cleaned out and scoped)
New Upper and Lower ball joints
New tie rods
They are using a synthetic ATF for the fluid.

Their alignment machine is good, calibrated -- aligning to 4WD specs from the service manual.
Most recent pump is tested and giving good pressure.

But no matter what they do, they cannot get the steering to cooperate. They say they are "all in" on finding a solution. They have contacted all of their experts, manufacturers, etc and everyone is scratching their heads.

Any thoughts? We're desperate. Anyone here had any similar issues?
Thanks in advance!!!

 

Were the lower ball joints OEM? These trucks are notoriously finicky, if it was aftermarket like moog, I’d go ahead and have them swap it out with OEM. If the LBJs are OEM, you may need to loosen the steering rack guide, it could be too tight.

 

I've replaced my steering rack with an aftermarket brand, no problem. My attitude is that my 2001 is so old, I don't need the steering rack to last another 24 years! When you say the steering feels "tight", do you mean it feels like when the engine is off, or is it just somewhat tougher? I guess both make me think the new steering rack may not be getting adequate hydraulic assist. This makes me want to focus on (listed in order of likelihood!):

1. They (WAAAAAAYYYYYY) over tightened the tie-rod ends back onto the LBJ.
2. The PS pump. I know you've indicated the PS pump was replaced, but are they following the correct PS rack air purge procedure? That is, turning the steering wheel lock to lock while adding PS fluid (Toyota uses ATF fluid) until the return PS fluid stops foaming/bubbling.
3. The hydraulic hoses to the steering rack were connected in reverse? This is a super stretch as the return line (to the PS pump) is just held on with a hose clamp while the pressure line FROM the PS pump to the rack has a threaded hose connection, but hey, maybe they just cut the hoses and put some pipe between them to splice back together?? I've seen weirder stuff!
4. The rotary valve in the rack where the steering column attaches is bad/clogged, not allowing enough hydraulic fluid to "assist" the steering rack. Kind of a long shot as you mentioned they've tried 4 different racks now.

I found the most difficult part by far when replacing my steering rack, was removing the threaded pipe part of the high pressure line from the PS pump, as the replacement lines didn't have that piece and I needed to re-use the old one. It was really tough to disconnect it from the old rack. But other than that, making sure the steering wheel was centered so that an equivalent amount of inner tie rod ends were sticking out of both sides of the steering rack was the only other "must pay attention to" part.

Let us know what it ends up being! Good luck!

 

Great advice!!! First thing Monday morning I will head over with a printout of these ideas -- will post back here once we (hopefully) find the solution.