Assembly
TOOL REQUIRED^ 926200000 Stand
^ 34099PA040 Installer B
^ 34099PA030 Installer A
^ 34099PA020 Guide Rack
^ 34099PA010 Installer
^ 34099PA100 Lock Nut Wrench
^ 927590000 Wrench
NOTE: Use only SUBARU genuine grease or equivalent for gearbox. Specified grease for gearbox. valiant grease M2. [Parts No. 003608001, net 0.5 kg (1.1 lbs.)]
1. Reassembly of rack assy.
a. Attach steering body assy to stand as shown. Apply a coat of grease to needle bearing.
NOTE: Use a special tool to support steering body assy. If steering body assy is removed from vehicle, be sure to remove rust and clean. Ensure that needle bearing is free from defects. If it is faulty, replace steering body assy with a new one
b. Using installers B and C, attach oil seal to installer A Insert installer A into rack assy from gear side. Remove oil seal from installer when it approaches piston and remove installer from rack assy. Face oil seal in the direction shown.
c. Install back-up ring from gear side of rack assy. installer C is furnished with installers B and C as a tool set for use on all Legacy models.
d. Apply a coat of grease to grooves in rack, sliding surface of sleeve and sealing surface of piston. Then insert rack assy into steering body assy from cylinder side.
NOTE: Be sure to apply grease so that it covers the entire surface of rack gear teeth. Do not allow grease to block air vent hole on rack.
e. Installation of holder assy. Attach guide to rack assy to prevent scratching cylinder, and apply a thin coat of grease to rack assy and guide.
f. Apply a coat of grease to inner wall of holder assy and O-ring, and install holder assy on steering body assy.
NOTE: Ensure that guide is free from scratches. Scratches may damage oil seal. Be careful not to damage oil seal lips when installing holder assy.
g. Apply a coat of grease to snap ring, and insert into groove in steering body assy. secure holder assy. Ensure that both ends of snap ring are close to pin hole when installed.
h. Attach installer to rack assy's cylinder. Using a press, install back-up ring and oil seal. Press installer until its groove is aligned with end of holder assy.
2. Installation of valve assy.
a. Remove traces of sealer, oil, rust, etc., from mating surfaces of valve housing and steering body assy.
b. Position a shim in graded portion of steering body assy's pinion housing, and apply an even coat of sealer (Fuji Bond: 004403004) to end of pinion housing.
NOTE: Use the same number of shims as that used when steering body assy was removed. If steering body assy, valve housing or pinion & valve assy is replaced with a new one, add two or three shims, install valve assy on pinion housing and tighten with two bolts to 20-29 Nm (14-22 ft. lbs.). Then, measure clearance between steering body assy and valve housing using a thickness gauge. Remove shims so that the clearance is zero.
c. Extend rack assy 75.9 mm (2.988 inch) beyond pinion side of steering body assy.
d. Apply grease to pinion gear teeth and ball bearing. Insert valve assy into Blue
e. Alternately and slowly tighten socket bolts. Replace faulty parts before installing valve assy. 0therwise, valve assy may not be installed properly. Tightening torque: 20-29 Nm (14-22 ft. lbs.).
3. Clean all parts and tools before reassembling.
a. Move rack shaft fully to the left and right two or three times to lubricate shaft ends with grease. Remove excess grease, being careful not to block air vent hole.
NOTE: When rack is fully moved to its stroke ends with tie-rod removed, be careful not to bump rack ends. Ensure that screw located at end of rack shaft is free from grease.
b. Apply grease to bore wall which accommodates sleeve. Ensure that hands are clean when applying grease.
c. Apply a coat of grease to sliding surface of pressure pad and seating surface of spring, and insert pressure pad into steering body assy. Charge adjusting screw with grease, insert spring into adjusting plug and install on steering body assy.
NOTE: The left and right tie-rod CP differ as indicated.
4. Installation of tie-rod CP:
a. Rotate input shaft until rack extends approximately 40 mm (1.57 inch).
b. Tighten adjusting plug until it will no longer tighten.
c. Install lock washers and tighten left and right tie-rod CPs into rack ends. Tightening torque: 69-88 Nm (51-65 ft. lbs.).
d. Using a chisel and hammer, bend lock washers (at two places). Be careful not to scratch rack.
5. Rack & pinion backlash adjustment
a. Loosen adjusting plug.
b. Rotate input shaft so that rack is in the straight ahead direction. Ensure that distance between rack end and stopper is 75.9 mm (2.988 inch).
c. Tighten adjusting plug by two threads.
d. Turn adjusting screw so that the entire thread area is coated with liquid packing.
e. Apply liquid packing of approximately 1.5 grams (0.053 oz) to adjusting screw thread area. Also turn plug to ensure that its entire contact area is coated with liquid packing. Liquid packing: Three-bond 1102 or equivalent.
f. Tighten adjusting plug to 20 Nm (14 ft. lbs.) and loosen, then tighten to 5 Nm (3.6 ft. lbs.) and loosen, and finally tighten to 5 Nm (3.6 ft. lbs.) and loosen 25°.
g. While holding adjusting plug using a closed wrench, tighten lock nut using lock nut wrench. Tightening torque: 59-74 Nm (43-54 ft. lbs.).
NOTE: Do not allow liquid packing to come in contact with pressure pad. While rotating input shaft to fully move rack shaft to the left and right, ensure that rack moves smoothly without binding, and that rotating torque is constant
6. Installation of boot:
a. Apply sealant to gearbox housing groove. Use accessory sealant for boot kit (P/N: 34099PA110)
b. Position boot large end in groove of gearbox, and small end in groove of tie-rod CP.
NOTE: Ensure that both ends of boot are properly situated in grooves. When installing another side boot, secure small end of boot first and then secure large end to prevent an increase in gearbox internal pressure. Ensure that boot is free from abnormal swelling or dents.
c. Wind two complete turns of lock wire on large end of boot, and twist it while pulling it upward with a force of approximately 29 - 49 N (7 - 11 lbs.). Then bend wire end along boot as shown.
(1) Wind up wire until it contacts boot.
(2) Ensure that lock wire is not loose.
d. Install clip using pliers. After installing clip, ensure that boot's small end is properly positioned in groove on tie-rod CP.
e. If tie-rod end was removed, screw in lock nut and tie-rod end to screwed portion of tie-rod, and tighten lock nut temporarily in a position as shown in the illustration. Pay attention to difference between right and left tie-rod ends. Identification mark:
- Left one: LH
- Right one: RH
7. Inspect near box assy 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 assy slowly at a radius one or two times as large as possible. After all, make sure that boot is installed in the specified position without deflation.
8. Install four pipes on gearbox. Tightening torque: 29-39 Nm (22-29 ft. lbs.).