Parts for your 2004 Toyota Highlander-Rack boots

2004 Toyota Highlander (Kluger) rack boots — what they do and when to replace them

Yes, rack boots are absolutely used on the 2004 Toyota Highlander (known as Kluger in Australia and New Zealand). Technical references including Toyota’s Service Information (TIS) Repair Manual for the steering section, the Toyota Electronic Parts Catalogue, and Haynes’ Toyota Highlander 2001–2007 manual all show a rack-and-pinion steering assembly with bellows-style rubber rack boots fitted on both sides to protect the inner tie rods and rack bar.

On this model, the rack boots act like flexible bellows that keep dust, grit, and water away from the polished rack shaft and inner tie rod joints. They also help maintain the light film of lubricant where it needs to be and allow the rack to move freely lock-to-lock. Left to crack or split, contaminants can chew out the inner joints and rack seals, leading to play in the steering, uneven tyre wear, and eventually a leaky power-steering rack. Many Toyota racks on this era also use a small breather/vent tube between the two boots — it must be reconnected so pressure balances properly when steering.

For a 2004 Highlander/Kluger, it’s smart practice to give the boots a quick look at every service or at least every 10,000–15,000 kilometres, especially if the vehicle sees gravel, beach work, or regular wet conditions. What to watch for:

• Cracks, splits, or perishing in the rubber bellows
• Loose, missing, or improvised clamps (cable ties aren’t ideal)
• Grit inside the boot, or a notchy feel when turning the wheel
• Power-steering fluid pooling inside the boot — a sign of an internal rack seal leak (the boot won’t fix that, the rack needs repair or replacement)

Replacement is straightforward for a competent home mechanic but does involve removing the outer tie rod end and sliding the boot off. Use quality, correct-size clamps (ear/Oetiker or OEM style), lightly lube the boot lip for installation, and refit the breather hose if present. Count the turns on the tie rod or measure the exposed thread to keep toe close, but a wheel alignment is still recommended after the job. If one boot has failed from age, doing both sides with genuine Toyota or reputable aftermarket parts is good value, and will help keep the steering tight and quiet.

Tip: If there’s fluid in the boot, don’t just replace the boot — that’s the rack telling a story. Plan for rack reseal or replacement and a fluid flush with the correct ATF-type power-steering fluid specified for this model.

• Does the 2004 Toyota Highlander/Kluger have steering rack boots?
  Yes. Both 2WD and AWD variants use a rack-and-pinion steering gear with bellows-style boots on each side, as shown in Toyota TIS steering diagrams and the Toyota parts catalogue. They’re essential for keeping contaminants out of the rack and inner tie rods.
• How often should rack boots be checked or replaced?
  Check them at every service or 10,000–15,000 km, and after any off-road or flood exposure. Replace at the first sign of cracking, tearing, loose clamps, or contamination. If fluid is found inside a boot, the rack’s internal seals are likely leaking and the rack needs attention.
• Do you need a wheel alignment after replacing rack boots?
  Usually, yes. Removing the outer tie rod to slide the boot off can alter toe. Marking positions helps, but getting an alignment afterwards is the safe bet for steering feel and tyre life.