Disassembly and Assembly
DISASSEMBLYRACK HOUSING ASSEMBLY
1) Disconnect the four pipes from gearbox.
NOTE: Remove the pipes E and F as a single unit being fixed at clamp plate.
2) Secure the gearbox removed from vehicle in vice using ST.
ST 926200000 STAND
CAUTION: Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST.
3) Remove the tie-rod end and lock nut from gearbox.
4) Remove the small clip from boot using pliers, and then move the boot to tie-rod end side.
5) Using a flat tip screwdriver, remove the band from boot.
6) Extend the rack approximately 40 mm (1.57 inch) out. Unlock the lock washer on both side of tie-rod end using a flat tip screwdriver.
CAUTION: Be careful not to scratch the rack surface as oil leaks may result.
7) Using the ST, loosen the lock nut.
ST 926230000 SPANNER
8) Tighten the adjusting screw until it no longer tightens.
9) Using a wrench [32 mm (1.26 inch) width across flats] or adjustable wrench, remove the tie-rod.
10) Loosen the adjusting screw, and then remove the spring and sleeve.
11) Remove the two bolts securing valve assembly.
12) Carefully draw out the input shaft, and then remove the valve assembly.
13) Using a sharp pointed pliers, rotate the rack stopper in direction of the arrow until end of the circlip comes out of stopper. Rotate the circlip in opposite direction and pull it out.
14) Pull the rack assembly from cylinder side, and draw out the rack bushing and rack stopper together with the rack assembly.
CAUTION: Be careful not to contact the rack to inner wall of cylinder when drawing out. Any scratch on the cylinder inner wall will cause oil leakage.
15) Remove the rack bushing and rack stopper from rack assembly.
16) Remove the oil seal from rack.
17) Insert the ST from pinion housing side, and then remove the oil seal using a press.
ST 34099FA110 INSTALLER
CONTROL VALVE
1) Disconnect the four pipes from gearbox.
NOTE: Remove the pipes E and F as a single unit being fixed at clamp plate.
2) Secure the gearbox removed from the vehicle in vise using ST.
ST 926200000 STAND
CAUTION: Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST.
3) Using the ST, loosen the lock nut.
ST 926230000 SPANNER
4) Tighten the adjusting screw until it no longer tightens.
5) Loosen the adjusting screw, and then remove the spring and sleeve.
6) Remove the two bolts securing valve assembly.
7) Carefully draw out the input shaft, and then remove the valve assembly.
8) Slide the dust cover out.
9) Using a press remove the pinion and valve assembly from valve housing.
10) Using the ST and press, remove the dust seal, oil seal and special bearing from valve housing.
ST 34099FA120 INSTALLER & REMOVER SEAL
CAUTION:
^ Do not apply force to the end surface of valve housing.
^ Do not reuse the oil seal after removal.
11) Remove the snap ring using snap ring pliers.
CAUTION: Be careful not to scratch the 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.
13) Remove the oil seal.
ASSEMBLY
RACK HOUSING ASSEMBLY
CAUTION: Use only SUBARU genuine grease for the gearbox.
Specified grease for gearbox: VALIANT GREASE M2 (Part No. 003608001)
1) Apply power steering fluid to a new oil seal.
2) Install the oil seal in correct position as shown in the figure. Push the oil seal using a press until portion A of ST contacts face of B.
ST 34099FA110 INSTALLER
CAUTION: Be careful not to damage or scratch the cylinder inner wall.
3) Fix the rack housing in vise using ST.
ST 926200000 STAND
CAUTION:
^ When fixing the rack housing in vise, be sure to use this special tool. Do not fix rack housing in vise using pad such as aluminum plates, etc.
^ When using the old rack housing, be sure to clean and remove rust before assembling. Check pinion housing bushing carefully.
4) Fit the 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
5) Apply genuine grease to the teeth of thoroughly washed rack assembly, and then fit the ST over the toothed portion.
CAUTION:
^ Be careful not to block the air passage with grease. Remove excessive grease.
^ After fitting cover, check the air passage hole for clogging. If clogged, open by removing grease from the hole.
6) Before inserting the rack assembly, apply a coat of specified power steering fluid to the surfaces of ST and rack piston.
7) Insert the rack assembly into rack housing from cylinder side, and then remove the ST after it has passed completely through oil seal.
8) Fit the ST1 and ST2 over the end of rack, and then install a new rack bushing.
ST1 926400000 GUIDE
ST 2927660000 GUIDE
CAUTION:
^ If burrs, or nicks are found on this guide and rack shaft portion, remove by filing.
^ Dip the rack bushing in specified power steering fluid before installing, and pay attention not to damage O-ring and oil seal.
9) 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.
10) Insert the rack stopper into the rack housing, and then wrap a new circlip using a sharp pointed pliers to secure the rack stopper in position.
CAUTION:
^ Be careful not to scratch the rack while winding circlip.
NOTE: Rotate the wrench another 90 to 180° after end of circlip has been wrapped in.
11) Apply genuine grease to dust cover, and then install the dust cover to valve assembly.
12) Apply genuine grease to the pinion gear and bearing of valve assembly.
13) Install a new gasket on valve assembly. Insert the valve assembly into place while facing rack teeth toward pinion.
14) Tighten the bolts alternately to secure valve assembly.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
CAUTION: Be sure to alternately tighten the bolts.
15) Temporarily install the rack, and then operate it from lock to lock two or three times to make it fit in. Remove the grease blocking air vent hole.
CAUTION: If operating the rack from lock to lock without installing tie-rod, it may damage the oil seal. Always install the tie-rods LH and RH.
16) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw and install on steering body.
17) Tighten the adjusting screw to specified torque.
Tightening torque:
First step; 7.4 Nm (0.75 kgf-m, 5.4 ft. lbs.)
Second step; Back off 25°.
18) Remove the tie-rod.
19) Verify that play is within specified value.
20) Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of adjusting screw thread.
Liquid gasket: THREE BOND 1141
21) Tighten the adjusting screw to specified torque.
Tightening torque:
First step; 7.4 Nm (0.75 kgf-m, 5.4 ft. lbs.)
Second step; Back off 25°.
22) Install the lock nut. While holding the adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER
Tightening torque (Lock nut): 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
23) Extend the rack approximately 40 mm (1.57 inch) beyond side of steering body.
24) Install the tie-rod and a new lock washer into rack.
Tightening torque: 78 Nm (8.0 kgf-m, 57.9 ft. lbs.)
25) Bend the lock washer.
CAUTION: Be careful not to scratch the rack when bending lock washer.
26) Apply a coat of grease to the tie-rod groove, and then install the boot to housing.
NOTE: Make sure that the boot is installed without unusual inflation or deflation.
27) Install a new boot band. Using band clamp pliers, caulk the boot band to make clearance of caulking part 2 mm (0.079 inch) or less.
28) Fix the boot end with clip (small).
29) After installing, check the boot end is positioned into groove on tie-rod.
30) If the tie-rod end was removed, screw in the lock nut and tie-rod end to screwed portion of tie-rod, and then tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length:
L 31.2 mm (1.23 inch)
31) Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock two or three times as quickly as possible.
"B" Holding the 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 specified position without deflation.
32) Remove the gearbox from ST.
ST 926200000 STAND
33) Install the four pipes on gearbox.
1) Connect the pipe A and B to 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 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 the ST2 to ST1.
ST1 34099FA120 INSTALLER & REMOVER SEAL
ST2 34099FA130 INSTALLER SEAL
4) To avoid scratching the oil seal, apply a coat of grease to the contact surface of installer and oil seal.
5) Verify the oil seal direction.
Attach the oil seal to installer and position in valve housing before pressing into place.
6) Press the oil seal into place using a press.
7) Attach the bearing to ST, and then position in value housing. Using the ST and press, install the special bearing in valve housing.
ST 34099FA120 INSTALLER & REMOVER SEAL
8) Put vinyl tape around the pinion shaft splines to protect oil seal from damage.
9) Fit the pinion and valve assembly into valve housing.
10) Secure the valve assembly to ST1 and ST2.
ST 1926370000 INSTALLER A
ST 234099FA100 STAND BASE
11) Apply specified power steering fluid to oil seal and ST3.
12) Install the ST3 to pinion, and then insert the oil seal. Press the oil seal using a press until ST4 contacts face end of valve housing.
ST3 926360000 INSTALLER A
ST4 927620000 INSTALLER B
13) Remove the ST3, and then fit the backing washer.
14) Force-fit the ball bearing using ST3.
ST1 926370000 INSTALLER A
ST2 34099FA100 STAND BASE
ST3 927640000 INSTALLER B
NOTE: Be careful not to tilt the ball bearing during installation.
15) Install the snap ring using snap ring pliers.
NOTE: Rotate the snap ring to check for proper installation.
16) Apply the specified grease to dust cover.
17) Install the dust cover on valve assembly.
18) Apply genuine grease to the pinion gear and bearing of valve assembly.
19) Install a new gasket on valve assembly. Insert the valve assembly into place while facing rack teeth toward pinion.
20) Tighten the bolts alternately to secure valve assembly.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
CAUTION: Be sure to alternately tighten the bolts.
21) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw and install on steering body.
22) Tighten the adjusting screw to specified torque.
Tightening torque:
First step; 7.4 Nm (0.75 kgf-m, 5.4 ft. lbs.)
Second step; Back off 25°.
23) Verify that play is within specified value.
24) Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of adjusting screw thread.
Liquid gasket: THREE BOND 1141
25) Tighten the adjusting screw to specified torque.
Tightening torque:
First step; 7.4 Nm (0.75 kgf-m, 5.4 ft. lbs.)
Second step; Backoff 25°.
26) Install the lock nut. While holding the adjusting screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut): 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
27) Remove the gearbox from ST.
28) Install the four pipes on 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 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.)