Rack Housing Assembly

Disconnect four pipes from gearbox.
Secure gearbox removed from vehicles in vise using ST.
1. ST 926200000 STAND
CAUTION: Secure the gearbox in a vise using the ST as shown. Do not attempt to secure it without this ST.

Fig 1: Removing Gearbox From Vehicle Using ST
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Remove tie-rod end and lock nut from gearbox.
Remove small clip from boot using pliers, and move boot to tie-rod end side.

Fig 2: Removing Small Clip From Boot
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Remove boot with large clips.

Fig 3: Removing Boot With Large Clips
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Extend rack approximately 40 mm (1.57 in) 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.

Fig 4: Unlocking Lock Wire At Lock Washer
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Using ST, loosen lock nut.
1. ST 926230000 SPANNER
Fig 5: Loosening Lock Nut Using ST
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Tighten adjusting screw until it no longer tightens.

Fig 6: Tightening Adjusting Screw
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Using a wrench [32 mm (1.26 in) 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.
Fig 7: Removing Tie-Rod
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Loosen adjusting screw and remove spring and sleeve.
CAUTION: Replace spring and/or sleeve if damaged.

Fig 8: Loosening Adjusting Screw And Removing Spring & Sleeve
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Remove two bolts securing valve assembly.

Fig 9: Removing Bolts Securing Valve Assembly
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Carefully draw out input shaft and remove valve assembly.

Fig 10: Drawing Out Input Shaft & Removing Valve Assembly
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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.

Fig 11: Removing Circlip Rotating Rack Stopper
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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.

Fig 12: Pulling Rack Assembly From Cylinder Side
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Remove rack bushing and rack stopper from rack assembly.
CAUTION: Do not reuse removed rack bushing and circlip.
Insert ST from pinion housing sides and remove oil seal using a press.
1. ST 34199AE050 OIL SEAL REMOVER
Fig 13: Removing Oil Seal Using Press
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Discard removed oil seal.