Rack Housing Assembly

WARNING: This page is about a different car, the 2004 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Use only SUBARU genuine grease for the gearbox.

Specified grease for gearbox:

VALIANT GREASE M2 (Part No. 003608001)

Apply power steering fluid to a new oil seal.
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
Courtesy of SUBARU OF AMERICA, INC.
Fix the rack housing in vise using ST.
ST 926200000 STAND
NOTE:
- 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.
Fit the ST over toothed portion of rack assembly, and check for binding or irregular insertion. If any deformation is noted on flats at the end of rack, shape by using file, and wash with cleaning fluid.

Fig 2: Fitting ST Over Toothed Portion Of Rack Assembly
Courtesy of SUBARU OF AMERICA, INC.
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.
Before inserting the rack assembly, apply a coat of specified power steering fluid to the surfaces of ST and rack piston.
Insert the rack assembly into rack housing from cylinder side, and then remove the ST after it has passed completely through oil seal.
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 filling.
- 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
Courtesy of SUBARU OF AMERICA, INC.
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.
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: Installing Circlip
Courtesy of SUBARU OF AMERICA, INC.
Apply genuine grease to dust cover, and then install the dust cover to valve assembly.

Fig 5: Installing Dust Cover To Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Apply genuine grease to the pinion gear and bearing of valve assembly.

Fig 6: Applying Genuine Grease To Pinion Gear And Bearing Of Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install a new gasket on valve assembly. Insert the valve assembly into place while facing rack teeth toward pinion.

Fig 7: Inserting Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts alternately to secure valve assembly.
Tightening torque:

25 N.m (2.5 kgf-m, 18.1 ft-lb)

CAUTION: Be sure to alternately tighten the bolts.
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.
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 And Seating Surface Of Spring
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to specified torque.
Tightening torque:

7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
After tightening to the specified tightening torque, loosen it by 25°.
Remove the tie-rod.
Verify that play is within specified value. < Ref. to SERVICE LIMIT <-- , INSPECTION, Steering Gearbox -->.>
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

Fig 9: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to specified torque.
Tightening torque:

7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
After tightening to the specified tightening torque, loosen it by 25°.
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 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.
Extend the rack approx. 40 mm (1.57 in) beyond side of steering body.
Install the tie-rod and a new lock washer into rack.
Tightening torque:

78 N.m (8.0 kgf-m, 57.9 ft-lb)

Fig 10: Identifying Rack Extending Dimension
Courtesy of SUBARU OF AMERICA, INC.
Bend the lock washer.
CAUTION: Be careful not to scratch the rack when bending lock washer.

Fig 11: Bending Lock Washer
Courtesy of SUBARU OF AMERICA, INC.
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
Courtesy of SUBARU OF AMERICA, INC.
Install a new boot band. Using band clamp pliers, caulk the boot band until caulking part clearance is 2 mm (0.079 in) or less.

Fig 13: Installing New Boot Band
Courtesy of SUBARU OF AMERICA, INC.
Fix the boot end with clip (small).

Fig 14: Fixing Boot End With Clip (Small)
Courtesy of SUBARU OF AMERICA, INC.
After installing, check the boot end is positioned into groove on tie rod.
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

Sedan:

25 mm (0.98 in)

Wagon:

15 mm (0.59 in)

Fig 15: Identifying Tie-Rod Length
Courtesy of SUBARU OF AMERICA, INC.
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
Courtesy of SUBARU OF AMERICA, INC.
Remove the gearbox from ST.
ST 926200000 STAND
Install the four pipes on gearbox.
1. Connect the pipe A and B to four pipe joints of gearbox.
  Tightening torque:
  
  13 N.m (1.3 kgf-m, 9.4 ft-lb)
2. Connect the pipe E and F to gearbox.
  Tightening torque:
  
  Pipe E: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
  
  Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)