Assembly
ASSEMBLYCAUTION: Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No.003608001)
1) Apply grease to teeth of rack so that grease applied is about as high as teeth, and also apply a thin film of grease to 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 or three times to squeeze grease which accumulates on both ends.
Remove grease to prevent it from choking air passage hole.
2) Apply grease to sleeve insertion hole.
3) Apply grease to 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.
4) Press-fit dust seal into gearbox housing while tapping it via a spanner or the like so that stepping between gearbox and dust seal is normally 2 mm (0.08 in).
Depth: A 2 mm (0.08 in)
5) Apply grease to sliding surface of sleeve and spring seat, then insert sleeve into pinion housing. Fit spring into sleeve screw, pack grease inside of screw, then install the screw.
6) Fit new lock washer on screwed portion of rack end.
Aligning cut portion of rack and nail of washer, screw in and tighten ball joint by using ST and spanner. ST 925700000 WRENCH
Tightening torque (Ball joint):
78 ± 10 Nm (8.0 ± 1.0 kg-m, 58 ± 7 ft-lb)
CAUTION: Pay attention to prevent rack surface on the right side from being damaged by a tool or the like, otherwise oil leakage might be caused.
NOTE; While tightening ball joint, hold rack with ST to prevent it from revolving.
7) Bend lock washer using a chisel.
CAUTION: Be careful not to scratch rack when bending lock washer.
8) Rack and pinion backlash adjustment
(1) Loosen adjusting screw.
(2) Rotate input shaft so that rack is in the straight ahead direction.
(3) Apply grease to sleeve.
(4) Tighten 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 adjusting screw 10 15 Nm (1.5 kg-m, 11 ft-lb) and back off 26°.
(7) Install lock nut. While holding adjusting screw with a wrench, tighten lock nul using ST. ST 926230000 SPANNER
Tightening torque (Lock nut):
39 ± 10 Nm (4.0 ± 1.0 kg-m, 29 ± 7 ft-Ib.)
NOTE:
- Hold adjusting screw with a wrench to prevent it from turning while tightening lock nut.
- Make adjustment so that steering wheel can be rotated fully from lock to lock without binding.
9) Check for service limit as per article of "Service limit". Make replacement and adjustment if necessary.
10) Install boot and mounting rubber to housing.
NOTE: Apply grease through small hole in boot.
11) Fit clip (large) to boot, and then install boot to gearbox while holding boot flange.
After installing boot, Told back boot flange to the extent that large clip can not be seen.
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.
1. The groove on gearbox
2. The groove on the rod
- Make sure that boot is installed without unusual inflation or deflation.
12) Turn boot until it seats well on gearbox and rubber mounting, then bend boot flange back.
13) Fix boot end with clip (small).
CAUTION: Use screwdriver with blunted tip to prevent boot from damage, when installing.
NOTE: After installing, check boot end is positioned into groove on tie-rod.
14) If tie-rod end was removed, screw in lock nut and tie- rod end to screwed portion of lie-rod, and tighten lock nut temporarily in a position as shown in figure.
Installed tie-rod length: L 15 mm (0.59 in)
NOTE: Pay attention to difference between right and left tie-rod ends.
15) Inspect 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 boot is installed in the specified position without deflation.
16) Remove gearbox from ST. ST 926200000 STAND
17) Install four pipes on gearbox.
(1) Connect pipes A and B to four pipe joints of gearbox. Connect upper pipe B first, and lower pipe A.
Tightening torque:
13 ± 3 Nm (1.3 ± 0.3 kg-m, 9.4 ± 2.2 ft-lb)
(2) Connect pipes C and D to gearbox. Connect lower pipe C first, and upper pipe D second.
Tightening torque:
15 ± 5 Nm (1.5 ± 0.5 kg-m, 10.8 ± 3.6 ft-lb)