Disassembly and Assembly
Steering GearboxDISASSEMBLY
RACK HOUSING ASSEMBLY
1. Disconnect four pipes from gearbox.
2. Secure gearbox removed from vehicle in vise using ST.
ST 926200000 STAND
CAUTION: Secure the gearbox in a vise 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 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.
11. Remove two bolts securing valve assembly.
12. Carefully draw out input shaft and remove valve assembly.
13. 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.
14. Pull rack assembly from cylinder side, and draw out rack bushing and rack stopper together with 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.
15. Remove rack bushing and rack stopper from rack assembly.
CAUTION: Do not reuse removed rack bushing and circlip.
16. Insert ST from pinion housing side and remove oil seal using a press.
ST 34199AE050 OIL SEAL REMOVER
NOTE: Discard removed oil seal.
CONTROL VALVE ASSEMBLY
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.
1. Using ST, loosen lock nut.
ST 926230000 SPANNER
2. Tighten adjusting screw until it no longer tightens.
3. Remove two bolts securing valve assembly.
4. Carefully draw out input shaft and remove valve assembly.
5. Draw out pinion and valve assembly from valve housing, using pipe of I.D. 44 to 46 mm (1.73 to 1.81 inch) and a press.
6. Pry off dust seal using screwdriver.
7. Remove snap ring using snap ring pliers.
8. Pry off oil seal using screwdriver.
CAUTION: After removing, check inside surface of valve housing for damage. If oil seal contacting surface is damaged, replace valve housing with a new one.
9. Remove snap ring using snap ring pliers.
CAUTION:
^ Do not reuse removed snap ring.
^ Be careful not to scratch pinion and valve assembly.
10. Press out bearing together with backing washer using pipe of ID 38.5 to 39.5 mm (1.516 to 1.555 inch) and press
CAUTION: Do not reuse removed bearing.
11. Remove oil seal
CAUTION: Do not reuse removed oil seal.
ASSEMBLY
RACK HOUSING 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. 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. Force-fit oil seal using ST.
ST 34199AE060 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.
7. Fixing rack housing. Fix rack housing in vise using ST.
ST 926200000 STAND
CAUTION:
^ When fixing 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 old rack housing, be sure to clean and remove rust before assembling. Check pinion housing bushing carefully.
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 teeth of thoroughly washed rack assembly, and fit ST over the toothed portion.
CAUTION:
^ Be careful not to block air passage hole 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 rack assembly into 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 damaOe O-ring and oil seal.
12. Insert rack stopper into cylinder tube until internal groove (on cylinder side) is aligned with external groove (on rack stopper). Turn rack stopper with ST so that rack stopper hole is seen through cylinder slits.
13. Insert rack stopper into rack housing, and wrap circlip using a sharp pointed pliers to secure rack stopper in position.
CAUTION: Be careful not to scratch rack while winding circlip.
NOTE: Rotate wrench another 90 to 180° after the end of circlip has been wrapped in.
14. Fit mounting rubber onto rack housing.
15. Apply genuine grease to pinion gear and bearing of valve assembly.
16. Install gasket on valve assembly. Insert valve assembly into 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.
17. Tighten bolts alternately to secure valve assembly.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
CAUTION: Be sure to alternately tighten bolts.
18. Install lock washers and tighten left and right tie-rods into rack ends.
Tightening torque: 78 Nm (8.0 kgf-m, 58 ft. lbs.)
19. Bend lock washer, using chisel.
CAUTION: Be careful not to scratch rack when bending lock washer.
20. 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 kgf-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 Nm (4.0 kgf-m, 29 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.
21. Inspect for service limit as per article of "Service limit".
22. 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.
23. 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.
24. Turn boot until it seats well on gearbox and rubber mounting, then bend boot flange back.
25. Fix boot end with clip (small).
CAUTION: After installing, check boot end is positioned into groove on tie-rod.
26. 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.
27. 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.
28. Remove gearbox from ST.
ST 926200000 STAND
29. 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 Nm (1.3 kgf-m, 9.4 ft. lbs.)
2. Connect pipes C and D to gearbox. Connect lower pipe C first, and upper pipe D second.
Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.)
CONTROL VALVE ASSEMBLY
Specified steering grease: VALIANT GREASE M2 (Part No. 003608001)
1. Clean all parts and tools before reassembling.
2. Press-fit oil seal into valve housing using ST and press.
ST 927610000 INSTALLER
NOTE: Before fitting, coat oil seal fully with ATF DEXRON ATF DEXRON III or equivalent.
3. Fit snap ring in snap ring groove using snap ring pliers.
CAUTION: Be careful not to scratch oil seal with snap ring pliers.
NOTE: Rotate snap ring to check for proper installation.
4. Put vinyl tape around pinion shaft splines to protect oil seal from damage.
5. Fit pinion and valve assembly into valve housing.
NOTE: Apply specified power steering fluid to outer diameter surface of input shaft and outer surface of valve body seal ring, and pay special attention not to damage seal when inserting pinion and valve assembly.
6. Secure valve assembly to ST1 and ST2.
7. Put ST3 over pinion, and insert oil seal, then force-fit oil seal into housing using ST4.
ST1 926370000INSTALLER A
ST2 927630000STAND BASE
ST3 926360000INSTALLER A
ST4 927620000INSTALLER B
NOTE:
^ Apply specified power steering fluid to oil seal and ST3, being careful not to damage oil seal lip.
^ Push oil seal until ST3 contacts housing end face.
8. Remove ST3, and fit backing washer.
9. Force-fit ball bearing using ST3.
STY 926370000 INSTALLER A
ST2 34099FA100 STAND BASE
ST3 927640000 INSTALLER B
NOTE: Be careful not to tilt ball bearing during installation.
10. Apply genuine grease to pinion gear and bearing of valve assembly.
11. Install gasket on valve assembly. Insert valve assembly into 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.
12. Tighten bolts alternately to secure valve assembly.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
CAUTION: Be sure to alternately tighten bolts.
13. Apply grease to sleeve insertion hole.
14. 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.
15. 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)
16. 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.
17. 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
1. Apply liquid packing to at least 1/3 of entire perimeter.
6. Tighten adjusting screw to 7.4 Nm (0.75 kgf-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 Nm (4.0 kgf-m, 29 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.
18. Check for service limit as per article of "Service limit".