Steering Gear: Service and Repair

REMOVAL





NOTE: For disassembly and assembly of gearbox unit, refer to section Control Valve (Power Steering Gearbox).

1. Disconnect battery minus terminal.
2. Remove air intake duct.
3. Loosen front wheel nut.
4. Lift vehicle and remove front wheels.
5. Remove front exhaust pipe assembly.

WARNING: Be careful, exhaust pipe is hot.





6. Using a puller, remove tie-rod end from knuckle arm after pulling off cotter pin and removing castle nut.





7. Remove jack-up plate and front stabilizer.





8. Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe.





9. Remove lower side bolt of universal joint, then remove upper side bolt and lift the joint upward.

NOTE: Place a mark on the joint and mating serration so that they can be re-installed at the original position.





10. Disconnect pipes C and D from pipe of gearbox.

CAUTION: Be careful not to damage these pipes.

NOTE: Disconnect upper pipe D first, and lower pipe C second.





11. Remove clamp bolts securing gearbox to crossmember, and remove gearbox.

DISASSEMBLY
1. Disconnect four pipes from gearbox.





2. Secure gearbox removed from 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 tie-rod end and lock nut from gearbox.





4. Remove small clip from boot using pliers, and move boot to tie-rod end side.





5. Remove boot together with large clips.





6. Extend rack approximately 40 mm (1.57 inch) out. Unlock 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.





7. Using ST, loosen lock nut.
ST 926230000 SPANNER





8. Tighten adjusting screw until it no longer tightens.





9. Using a wrench [32 mm (1.26 inch) width across flats or adjustable wrench, remove 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.

10. Loosen adjusting screw and remove spring and sleeve.

CAUTION: Replace spring and/or sleeve if damaged.

INSPECTION





1. Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary.
2. When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.

SERVICE LIMIT








Make a measurement as follows. If it exceeds the specified service limit, adjust or replace.

NOTE: When making a measurement, vise gearbox by using ST. Never vise gearbox by inserting aluminum plates, etc. between vise and gearbox.

ST 926200000 STAND
Sliding resistance of rack shaft:
Service limit 235.0 N (24.0 kg, 52.9 lb) or less

RACK SHAFT PLAY IN RADIAL DIRECTION








Right-turn steering:
Service limit 0.19 mm (0.0075 inch) or less
On condition
L: 5 mm (0.20 inch)
P: 122.6 N (12.5 kg, 27.6 lb)
Left-turn steering:
Service limit Direction < c > 0.3 mm (0.012 inch) or less
Direction 0.15 mm (0.0059 inch) or less

INPUT SHAFT PLAY








In radial direction:
Service limit 0.18 mm (0.0071 inch) or less
On condition P: 98 N (10 kg, 22 lb)
In axial direction:
Service limit 0.5 mm (0.020 inch) or less
On condition P: 20 - 49 N (2 - 5 kg, 4 - 11 lb)

TURNING RESISTANCE OF GEARBOX





Using ST, measure gearbox turning resistance.
ST 926230000 SPANNER
Service limit: Straight-ahead position within 30 mm (1.18 inch) from rack center Less than 11.18 N (1.14 kg, 2.51 lb)
Maximum allowable resistance 12.7 N (1.3 kg, 2.9 lb)

ASSEMBLY

CAUTION: Use only SUBARU genuine grease for gearbox.

Grease: VALIANT GREASE M2 Part No. 003608001, net 0.5 kg (1.1 lb)]
1. Clean all parts and tools before reassembling.
2. 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 2 or three 3 times to squeeze grease which accumulates on both ends. Remove grease to prevent it from choking air passage hole.

3. Apply grease to sleeve insertion hole.
4. 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.








5. 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 inch).

Depth: A 2 mm (0.08 inch)





6. 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.





7. Install lock washers and tighten left and right tie-rods into rack ends.
On condition L: Approximately 40 mm (1.57 inch)
Tightening torque: 78 ± 10 Nm (8.0 ± 1.0 kg-m, 58 ± 7 ft. lbs.)





8. Bend lock washer using a chisel.

CAUTION: Be careful not to scratch rack when bending lock washer.





9. 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 to 7.4 Nm (0.75 kg-m, 5.4 ft. lbs.) and back off 25°.
7. Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut): 39 ± 10 Nm (4.0 ± 1.0 kg-m, 29 ± 67 ft. lbs.)

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.

10. Check for service limit as per article of "Service limit". Make replacement and adjustment if necessary.
11. Install boot to 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 boot is installed without unusual inflation or deflation.





12. Fit clip (large) to boot, and then install boot to gearbox while holding boot flange. After installing boot, fold back boot flange to the extent that large clip cannot be seen.





13. Turn boot until it seats well on gearbox and rubber mounting, then bend boot flange back.





14. Fix boot end with clip (small).

CAUTION: After installing, check boot end is positioned into groove on tie-rod.





15. 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 figure.
Installed tie-rod length: L 15 mm (0.59 inch)

NOTE: Pay attention to difference between right and left tie-rod ends.





16. 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.
17. Remove gearbox from ST.
ST 926200000 STAND
18. 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. lbs.)





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. lbs.)

INSTALLATION
1. Insert gearbox into crossmember, being careful not to damage gearbox boot.





2. Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque.
Tightening torque: 59 ± 12 Nm (6.0 ± 1.2 kg-m, 43 ± 9 ft. lbs.)
3. How to install the joint.
1. Push the long yoke of the joint, all the way into the serrated portion of the steering shaft, setting the bolt hole in the cutout.
2. Then pull the short yoke all way out of the serrated portion of the gear box, setting the bolt hole in the cutout.
3. Insert the bolt through the short yoke, pull the joint and confirm that the bolt is on cutout of the gearbox.





4. Fasten the short yoke side with a spring washer and bolt, then fasten the long yoke side.
Tightening torque: 24 ± 3 Nm (2.45 ± 0.3 kg-m, 17.4 ± 2.2 ft. lbs.)





4. Connect tie-rod end and knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock.
Castle nut tightening torque: Tighten to 27.0 ± 2.5 Nm (2.75 ± 0.25 kg-m, 19.9 ± 1.8 ft. lbs.), and tighten further within 60� until cotter pin hole is aligned with a slot in the nut.

CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.

5. Install front stabilizer to vehicle.





6. Install front exhaust pipe assembly.
7. Install tires.
8. Tighten wheel nuts to the specified torque.
Tightening torque: 88 ± 10 Nm (9.0 ± 1.0 kg-m, 65 ± 7 ft. lbs.)
9. Install air intake duct.
10. Connect ground cable to battery.
11. Pour fluid into oil tank, and bleed air.
12. Check for fluid leaks.
13. Install jack-up plate.

WARNING: Be careful, exhaust manifold is hot.

14. Lower vehicle.
15. Check fluid level in oil tank.
16. After adjusting toe-in and steering angle, tighten lock nut on tie-rod end.
Tightening torque: 83 ± 5 Nm (8.55 ± 0.5 kg-m, 61.5 ± 3.6 ft. lbs.)

CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.

ADJUSTMENT





1. Adjust front toe.
Standard of front toe: IN 3-OUT 3 mm (IN 0.12-OUT 0.12)





2. Adjust steering angle of wheels.
Standard of steering angle:





3. If steering wheel spokes are not horizontal when wheels are set in the straight ahead position, and error is more than 5° on the periphery of steering wheel, correctly re-install the steering wheel.





4. If steering wheel spokes are not horizontal with vehicle set in the straight ahead position after this adjustment, correct it by turning the right and left tie-rods in the same direction by the same turns.

Reservoir Tank
REMOVAL
1. Drain about 0.3 e (0.3 US qt. 0.3 Imp qt) of working fluid from the reservoir tank.





2. Disconnect pipe D from return hose and suction hose from oil pump.

CAUTION:
- Do not allow fluid from the hose end to come into contact with pulley belt.
- To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth.

3. Remove reservoir tank from bracket by pulling it upwards.

INSTALLATION
1. Install reservoir tank to bracket.





2. Connect pipes D to return hose and suction hose to oil pump.
3. Feed the specified power steering fluid and discharge air.