Part 2 of 2
ASSEMBLYRACK 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 tierod 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 damage 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-cm, 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-cm, 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-cm, 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-cm, 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. Make replacement and adjustment if necessary.
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-cm, 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-cm, 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 926370000 INSTALLER A
ST2 927630000 STAND BASE
ST3 926360000 INSTALLER A
ST4 927620000 INSTALLER 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.
ST1 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-cm, 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
6. Tighten adjusting screw to 7.4 Nm (0.75 kgf-cm, 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 S PAN N E R
Tightening torque (Lock nut): 39 Nm (4.0 kgf-cm, 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. Make replacement and adjustment if necessary.
INSPECTION
BASIC 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 304 N (31 (kgs, 68 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 (kgs, 27.6 lb)
Left-turn steering:
Service limit
Direction 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 (kgs, 22 lb)
In axial direction:
Service limit 0.5 mm (0.020 inch) or less
On condition
P: 20-49 N (2-5 (kgs, 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 (kgs, 2.51 lb)
Maximum allowable resistance 12.7 N (1.3 (kgs, 2.9 lb)
OIL LEAKING
^ Oil leaking points
1. If leak point is other than a, b, c, or d, perform the 5th step in Oil leak check procedure and replacement parts before dismounting gearbox from vehicle. If gearbox is dismounted without confirming where the leak is, it must be mounted again to locate the leak point.
2. Even if the location of the leak can be easily found by observing the leaking condition, it is necessary to thoroughly remove the oil from the suspected portion and turn the steering wheel from lock to lock about 30 to 40 times with engine running, then make comparison of the suspected portion between immediately after and several hours after this operation.
3. Before starting oil leak repair work, be sure to clean the gearbox, hoses, pipes, and surrounding parts. After completing repair work, clean these areas again.
^ Oil leak check procedure and replacement parts
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. Leakage from "a" The oil seal is damaged. Replace valve assembly with a new one.
2. Leakage from "b"
The torsion bar O-ring is damaged. Replace valve assembly with a new one.
3. Leakage from "c"
The oil seal is damaged. Replace valve assembly or oil seal with a new one.
4. Leakage from "d"
The pipe is damaged. Replace the faulty pipe or O-ring.
5. If leak is other than a, b, c, or d, and if oil is leaking from the gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove oil from the surrounding portions. Then, turn the steering wheel from lock to lock 30 to 40 times with the engine running, then make comparison of the leaked portion immediately after and several hours after this operation.
1. Leakage from "e"
The cylinder seal is damaged. Replace rack bush with a new one.
2. Leakage from "f"
There are two possible causes. Take following step first. Remove the pipe assembly B from the valve housing, and close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40 times with the engine running, then make comparison of the leaked portion between them
CAUTION:
^ If leakage from f is noted again: The oil seal of pinion and valve assembly is damaged. Replace pinion and valve assembly with a new one. Or replace the oil seal and the parts that are damaged during disassembly with new ones.
^ If oil stops leaking from f: The oil seal of rack housing is damaged. Replace the oil seal and the parts that are damaged during disassembly with new ones.
ADJUSTMENT
1. Adjust front toe.
Standard of front toe: IN 3-OUT 3 mm (IN 0.12-OUT 0.12 inch)
2. Adjust steering angle of wheels.
Standard of steering angle:
Inner wheel 34.5° ± 1.5°
Outer wheel 30.3° ± 1.5°
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.