LEMON Manuals: Even more car manuals for everyone
Home >> Subaru >> 2003 >> Forester XS, Automatic >> Repair and Diagnosis >> Steering >> Manual Steering >> Power Assisted System (Power Steering) >> Steering Gearbox >> Assembly >> Rack Housing Assembly

Rack Housing Assembly

CAUTION: Use only SUBARU genuine grease for the gearbox.
  1. 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.
    Fig 1: Installing Oil Seal In Correct Position
    G02097273Courtesy of SUBARU OF AMERICA, INC.
  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

    Fig 2: Fitting Cover & Remover Over Toothed Portion Of Rack Assembly
    G02097274Courtesy of SUBARU OF AMERICA, INC.
  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

    ST2 927660000 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.
    Fig 3: Installing Rack Bushing Assembly
    G02097275Courtesy of SUBARU OF AMERICA, INC.
  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.
    Fig 4: Inserting Rack Stopper Into Rack Housing
    G02097276Courtesy of SUBARU OF AMERICA, INC.
  11. Apply genuine grease to dust cover, and then install the dust cover to valve assembly.
    Fig 5: Applying Genuine Grease To Dust Cover
    G02097277Courtesy of SUBARU OF AMERICA, INC.
  12. Apply genuine grease to the pinion gear and bearing of valve assembly.
    Fig 6: Applying Genuine Grease To Pinion Gear & Bearing Of Valve Assembly
    G02097278Courtesy of SUBARU OF AMERICA, INC.
  13. Install a new gasket on valve assembly. Insert the valve assembly into place while facing rack teeth toward pinion.
    Fig 7: Installing Gasket On Valve Assembly
    G02097279Courtesy of SUBARU OF AMERICA, INC.
  14. Tighten the bolts alternately to secure valve assembly.
    1. Tightening torque:  25 N.m (2.5 kgf-m, 18.1 ft-lb)
    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.

    Fig 8: Applying Coat Of Grease To Sliding Surface Of Sleeve & Seating Surface Of Spring
    G02097280Courtesy of SUBARU OF AMERICA, INC.
  17. Tighten the adjusting screw to specified torque.

    Tightening torque: 

    1. First step;  7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
    2. Second step;  Back off 25°
  18. Remove the tie-rod.
  19. Verify that play is within specified value. Refer to SERVICE LIMIT  , INSPECTION, Steering Gearbox.
  20. Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of adjusting screw thread.
    1. Liquid gasket:  THREE BOND 1141
    Fig 9: Applying Liquid Gasket To Entire Perimeter Of Adjusting Screw Thread
    G02097281Courtesy of SUBARU OF AMERICA, INC.
  21. Tighten the adjusting screw to specified torque.

    Tightening torque: 

    1. First step;  7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
    2. 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

    1. Tightening torque (Lock nut):  39 N.m (4.0 kgf-m, 28.9 ft-lb)
    NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
  23. Extend the rack approx. 40 mm (1.57 in) beyond side of steering body.
  24. Install the tie-rod and a new lock washer into rack.
    1. Tightening torque:  78 N.m (8.0 kgf-m, 57.9 ft-lb)
    Fig 10: Extending Rack Beyond Side Of Steering Body
    G02097282Courtesy of SUBARU OF AMERICA, INC.
  25. Bend the lock washer.
    CAUTION: Be careful not to scratch the rack when bending lock washer.
    Fig 11: Bending Lock Washer
    G02097283Courtesy of SUBARU OF AMERICA, INC.
  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.
    Fig 12: Applying Coat Of Grease To Tie-Rod Groove
    G02097284Courtesy of SUBARU OF AMERICA, INC.
  27. Install a new boot band. Using band clamp pliers, caulk the boot band to make clearance of caulking part 2 mm (0.079 in) or less.
    Fig 13: Installing New Boot Band
    G02097285Courtesy of SUBARU OF AMERICA, INC.
  28. Fix the boot end with clip (small).
    Fig 14: Fixing Boot End With Clip (Small)
    G02097286Courtesy of SUBARU OF AMERICA, INC.
  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.
    1. Installed tie-rod length: L  31.2 mm (1.23 in)
    Fig 15: Tightening Lock Nut Temporarily
    G02097287Courtesy of SUBARU OF AMERICA, INC.
  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.

    Fig 16: Inspecting Gearbox
    G02097288Courtesy of SUBARU OF AMERICA, INC.
  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.
      1. Tightening torque:  13 N.m (1.3 kgf-m, 9.4 ft-lb)
    2. Connect the pipe E and F to gearbox.

      Tightening torque: 

      1. Pipe E:  15 N.m (1.5 kgf-m, 10.8 ft-lb)
      2. Pipe F:  25 N.m (2.5 kgf-m, 18.1 ft-lb)
scientia non olet · About LEMON Manuals