Disassembly and Assembly
Steering GearboxDISASSEMBLY
NOTE: Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevitable damage to some related parts must be taken into account, and spare parts for them must also be prepared. However, it is essential to pinpoint the cause of trouble, and limit the number of replacement parts as much as possible.
RACK HOUSING ASSEMBLY
1. Disconnect the four pipes from the gearbox.
NOTE: Remove the pipes E and F as a single unit being fixed at the clamp plate.
2. Secure the gearbox removed from the vehicle in vice using ST.
ST 926200000 STAND
CAUTION: Secure the gearbox in a vice using the ST as shown. Do not attempt to secure it without this ST.
3. Remove the tie-rod end plate.
4. Remove the tie-rod end and lock nut from the gearbox.
5. Remove the small clip from the boot using pliers, and move the boot to the tie-rod end side.
6. Using standard screwdriver, remove the band from the boot.
7. Extend the rack approximately 40 mm (1.57 inch) out. Unlock the lock wire at lock washer on each side of tie-rod end using a standard screwdriver.
CAUTION: Be careful not to scratch rack surface as oil leaks may result.
8. Using ST, loosen the lock nut.
ST 926230000 SPANNER
9. Tighten the adjusting screw until it no longer tightens.
10. Using a wrench [32 mm (1.26 inch) width across flats] or adjustable wrench, remove the tie-rod.
CAUTION:
^ Check ball joint for free play, and tie-rod for bends. Replace if necessary.
^ Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary.
11. Loosen the adjusting screw and remove the spring and sleeve.
CAUTION: Replace spring and/or sleeve if damaged.
12. Remove the two bolts securing valve assembly.
13. Carefully draw out the input shaft and remove the valve assembly.
14. Using a sharp pointed pliers, rotate the rack stopper in the direction of the arrow until the end of the circlip comes out of the stopper. Rotate the circlip in the opposite direction and pull it out.
15. Pull the rack assembly from the cylinder side, and draw out the rack bushing and rack stopper together with the rack assembly.
CAUTION: Be careful not to contact rack to inner wall of cylinder when drawing out. Any scratch on cylinder inner wall will cause oil leakage.
16. Remove the rack bushing and rack stopper from the rack assembly.
CAUTION: Do not reuse removed rack bushing and circlip.
17. Remove the oil seal from rack.
18. Insert ST from the pinion housing side and remove the oil seal using a press.
ST 34099FA110 INSTALLER
NOTE: Discard the removed the oil seal.
CONTROL VALVE
1. Disconnect the four pipes from the gearbox.
NOTE: Remove the pipes E and F as a single unit being fixed at the clamp plate.
2. Secure the gearbox removed from the vehicle in vice using ST.
ST 926200000 STAND
CAUTION: Secure the gearbox in a vice using the ST as shown. Do not attempt to secure it without this ST.
3. Using ST, loosen the lock nut.
ST 926230000 SPANNER
4. Tighten the adjusting screw until it no longer tightens.
5. Loosen the adjusting screw and remove the spring and sleeve.
CAUTION: Replace the spring and/or sleeve if damaged.
6. Remove the two bolts securing valve assembly.
7. Carefully draw out the input shaft and remove the valve assembly.
8. Slide the dust cover out.
9. Using a press remove pinion and valve assembly from the valve housing.
10. Using ST and press, remove the dust seal, oil seal and special bearing from the valve housing.
ST 34099FA120 INSTALLER & REMOVER SEAL
CAUTION:
^ Do not apply a force to end surface of valve housing.
^ Do not reuse oil seal after removal.
11. Remove the snap ring using snap ring pliers.
CAUTION:
^ Do not reuse removed snap ring.
^ Be careful not to scratch pinion and valve assembly.
12. Press out the bearing together with the back up washer using pipe of I.D. 38.5 to 39.5 mm (1.51 6 to 1.555 inch) and press.
CAUTION: Do not reuse removed bearing.
13. Remove the oil seal.
CAUTION: Do not reuse removed oil seal.
ASSEMBLY
RACK HOUSING ASSEMBLY
CAUTION: Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox: VALIANT GREASE M2 (Part No. 003608001)
1. Clean all parts and tools before reassembling
2. Force-fit oil seal using ST.
ST 34099FA110 INSTALLER
CAUTION: Be careful not to damage or scratch cylinder inner wall.
NOTE:
^ Apply specified power steering fluid to oil seal
^ Pay special attention not to install oil seal in wrong direction.
^ Push oil seal until the stepped portion of A contacts end face of B.
3. Apply grease to the teeth of rack so that the grease applied is about as high as teeth, and also apply a thin film of grease to the sliding portion of rack shaft.
CAUTION:
^ When moving rack to stroke end without tie-rod attached, prevent shocks from being applied at the end.
^ Do not apply grease to threaded portion at end of rack shaft.
^ Move rack shaft to stroke end two (2) or three (3) times to squeeze grease which accumulates on both ends. Remove grease to prevent it from choking air passage hole.
4. Apply grease to the sleeve insertion hole
5. Apply grease to the dust seal insertion hole
CAUTION: Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged.
6. Fixing rack housing
Fix the rack housing in vice using ST
ST 926200000 STAND
CAUTION:
^ When fixing rack housing in vice, be sure to use this special tool. Do not fix rack housing in vice using pad such as aluminum plates, etc.
^ When using old rack housing, be sure to clean and remove rust before assembling. Check pinion housing bushing carefully.
7. Install the oil seal to rack.
8. Fit ST over toothed portion of rack assembly, and check for binding or unsmooth insertion If any deformation is noted on flats at the end of rack, shape by using file, and wash with cleaning fluid
ST 926390001 COVER & REMOVER
9. Apply genuine grease to the teeth of thoroughly washed rack assembly, and fit ST over the toothed portion.
CAUTION:
^ Be careful not to block air passage with grease. Remove excessive grease.
^ After fitting cover, check air passage hole for clogging. If clogged, open by removing grease from the hole.
^ Check rack shaft for damage.
^ Apply specified power steering fluid to this ST and surface of piston ring to prevent seal from being damaged.
10. Insert the rack assembly into the rack housing from cylinder side, and remove ST after it has passed completely through oil seal.
NOTE: Before inserting rack assembly, apply a coat of specified power steering fluid to surfaces of ST and rack piston.
ST 926390001 COVER & REMOVER
11. Fit ST1 and ST2 over the end of rack, and install rack bushing.
ST1 926400000 GUIDE
ST2 927660000 GUIDE
CAUTION:
^ If burrs, or nicks are found on this guide and rack shaft portion, remove by filing.
^ Dip rack bushing in specified power steering fluid before installing, and pay attention not to damage O-ring and oil seal.
12. Insert the rack stopper into the cylinder tube until internal groove (on cylinder side) is aligned with external groove (on rack stopper). Turn the rack stopper with ST so that the rack stopper hole is seen through cylinder slits.
13. Insert the rack stopper into the rack housing, and wrap the circlip using a sharp pointed pliers to secure the rack stopper in position.
CAUTION: Be careful not to scratch rack while winding circlip.
NOTE: Rotate the wrench another 90 to 180° after the end of circlip has been wrapped in.
14. Fit the mounting rubber onto the rack housing.
15. Apply the specified grease to the dust cover.
16. Install the dust cover on the valve assembly.
17. Apply genuine grease to the pinion gear and bearing of valve assembly.
18. Install the gasket on the valve assembly. Insert the valve assembly into the place while facing rack teeth toward pinion.
CAUTION: Be sure to use a new gasket.
NOTE: Do not allow packing to be caught when installing valve assembly.
19. Tighten the bolts alternately to secure the valve assembly.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
CAUTION: Be sure to alternately tighten bolts.
20. Apply grease to the sliding surface of sleeve and spring seat, then insert the sleeve into the pinion housing. Fit the spring into the sleeve screw, pack grease inside of screw, then install the screw.
21. Install the lock washers and tighten the left and right tie-rods into the rack ends.
On condition
L: Approximately 40 mm (1.57 inch)
Tightening torque: 78 Nm (8.0 kgf-m, 58 ft. lbs.)
22. Bend the lock washer using a chisel.
CAUTION: Be careful not to scratch rack when bending lock washer.
23. Rack and pinion backlash adjustment
1. Loosen the adjusting screw.
2. Rotate the input shaft so that the rack is in the straight ahead direction.
3. Apply grease to the sleeve.
4. Tighten the adjusting screw by two threads.
5. Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread.
Liquid packing: THREE BOND 1141
1. Apply liquid packing to at least 1/3 of entire perimeter.
6. Tighten the adjusting screw to 7.4 Nm (0.75 kgf-m, 5.4 ft. lbs.) and back off 25°.
7. Install the lock nut. While holding adjusting screw with a wrench, tighten the lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut): 39 Nm (4.0 kgf-m, 29 ft. lbs.)
NOTE:
^ Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
^ Make adjustment so that the steering wheel can be rotated fully from lock to lock without binding.
24. Check for service limit as per article of "Service limit". Make replacement and adjustment if necessary.
25. Install the boot to the housing.
NOTE:
^ Before installing boot, be sure to apply grease to the groove of tie-rod.
^ Install fitting portions of boots to the following portions in both sides of assembled steering gearbox.
The groove on gearbox The groove on the rod
^ Make sure that the boot is installed without unusual inflation or deflation.
26. Using a screwdriver, tighten the screw until the ends "A" and "B" of the band come into contact with each other.
CAUTION: Use a new band.
NOTE: Always tighten the band from the underside of the gear box.
27. Fix the boot end with clip (small).
CAUTION: After installing, check boot end is positioned into groove on tie-rod.
28. If the tie-rod end was removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in figure.
Installed tie-rod length: L 15 mm (0.59 inch)
29. Install the tie-rod end plate.
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)
30. Inspect the gearbox as follows: "A" Holding tie-rod end, repeat lock to lock two or three times as quickly as possible. "B" Holding tie-rod end, turn it slowly at a radius one or two times as large as possible. After all, make sure that the boot is installed in the specified position without deflation.
31. Remove gearbox from ST.
ST 926200000 STAN D
32. Install the four pipes on gearbox.
1. Connect the pipe A and B to the four pipe joints of gearbox.
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)
2. Connect the pipe E and F to the gearbox.
Tightening torque:
Pipe E: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.)
Pipe F: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
CONTROL VALVE ASSEMBLY
Specified steering grease: VALIANT GREASE M2 (Part No. 003608001)
1. Clean all parts and tools before reassembling.
2. Apply a coat of specified power steering fluid to the inner wall of valve housing.
3. Attach ST2 to ST1, and press the oil seal into the place using a press.
ST1 34099FA120 INSTALLER & REMOVER SEAL
ST2 34099FA130 INSTALLER SEAL
1. Face oil seal in the direction shown in figure when installing.
2. To avoid scratching oil seal, apply a coat of grease to the contact surface of installer and oil seal.
3. To facilitate installation, attach oil seal to the installer and position in valve housing before pressing into place.
4. Using ST and press, install the special bearing in valve housing.
ST 34099FA120 INSTALLER & REMOVER SEAL
NOTE: To facilitate installation, attach the ball bearing to the remover and position in valve housing before pressing it into place.
5. Put vinyl tape around pinion shaft splines to protect oil seal from damage.
6. Fit pinion and valve assembly into valve housing.
7. Secure valve assembly to ST1 and ST2.
8. Put ST3 over pinion, and insert oil seal, then force-fit oil seal into housing using ST4.
ST1 926370000 INSTALLER A
ST2 34099FA100 STAND BASE
ST3 926360000 INSTALLER A
ST4 927620000 INSTALLER B
NOTE:
^ Apply the specified power steering fluid to the oil seal and ST3, being careful not to damage oil seal lip.
^ Push the oil seal until ST3 contacts housing end face.
9. Remove ST3, and fit backing washer.
10. Force-fit ball bearing using ST3.
ST1 926370000 INSTALLER A
ST2 34099FA100 STAND BASE
ST3 927640000 INSTALLER B
NOTE: Be careful not to tilt ball bearing during installation.
11. Install the snap ring using snap ring pliers.
NOTE: Rotate the snap ring to check for proper installation.
12. Apply the specified grease to the dust cover.
13. Install the dust cover on the valve assembly.
14. Apply genuine grease to the pinion gear and bearing of valve assembly.
15. Install the gasket on the valve assembly. Insert the valve assembly into the place while facing rack teeth toward pinion.
CAUTION: Be sure to use a new gasket.
NOTE: Do not allow packing to be caught when installing valve assembly.
16. Tighten the bolts alternately to secure the valve assembly.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
CAUTION: Be sure to alternately tighten bolts.
17. Apply grease to the sleeve insertion hole.
18. Apply grease to the dust seal insertion hole.
CAUTION: Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged.
19. Apply grease to the sliding surface of sleeve and spring seat, then insert the sleeve into the pinion housing. Fit the spring into the sleeve the screw, pack grease inside of screw, then install the screw.
20. Rack and pinion backlash adjustment
1. Loosen the adjusting screw.
2. Rotate the input shaft so that the rack is in the straight ahead direction.
3. Apply grease to the sleeve.
4. Tighten the adjusting screw by two threads.
5. Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread.
Liquid packing: THREE BOND 1141
6. Tighten the adjusting screw to 7.4 Nm (0.75 kgf-m, 5.4 ft. lbs.) and back off 25°.
7. Install the lock nut. While holding adjusting screw with a wrench, tighten the lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut): 39 Nm (4.0 kgf-m, 29 ft. lbs.)
NOTE:
^ Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
^ Make adjustment so that the steering wheel can be rotated fully from lock to lock without binding.
21. Check for service limit as per article of "Service limit". Make replacement and adjustment if necessary.
22. Take off the gearbox from ST.
23. Install the four pipes on the gearbox.
1. Connect the pipe A and B to the gearbox.
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)
2. Connect the pipe E and F to the gearbox.
Tightening torque:
Pipe E: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.)
Pipe F: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)