Steering Gearbox: Disassembly

Disconnect the four pipes from steering body and control valve housing.

Fig 1: Identifying Steering Body And Control Valve Housing Pipes
Courtesy of SUBARU OF AMERICA, INC.
Secure the gearbox removed from vehicle in a vise using ST.
CAUTION: Secure the gearbox assembly in a vise using ST as shown. Do not secure the gearbox without this ST.

PREPARATION TOOL:

ST1: STAND (926200000)

ST2: BOSS D (34199AG000)
1. Replace BOSS of STAND (ST1) with BOSS D (ST2).
2. Using the clamp (a) removed from vehicle body, attach the gearbox assembly to ST.
  
  Fig 2: Securing Gearbox Assembly In Vise Using ST
  Courtesy of SUBARU OF AMERICA, INC.
Remove the left and right boots from the gearbox.
1. Remove the tie-rod end and lock nut (a) from gearbox.
2. Remove the clip (b) located outside the boot using the pliers, and then slide the boot to the tie-rod end side.
  
  Fig 3: Removing Tie-Rod End And Boot Clip Using Pliers
  Courtesy of SUBARU OF AMERICA, INC.
3. Using a flat tip screwdriver, remove the band from boot.
  NOTE: Replace the boot if there is damage, cracks or deterioration.
  
  Fig 4: Removing Boot Band Using Flat Tip Screwdriver
  Courtesy of SUBARU OF AMERICA, INC.
Remove the left and right tie-rods.
1. Using the ST, loosen the lock nut.
  PREPARATION TOOL:
  
  ST: SPECIAL TOOL CPS (34199AJ060)
2. Tighten the adjusting screw (a) until it can no longer be tightened.
  
  Fig 5: Loosening Lock Nut Using ST
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the tie-rod.
  
  Fig 6: Removing Tie-Rod
  Courtesy of SUBARU OF AMERICA, INC.
Remove the control valve.
1. Loosen the adjusting screw (a), and remove the spring (b) and sleeve (c).
  
  Fig 7: Identifying Adjusting Screw, Spring And Sleeve
  Courtesy of SUBARU OF AMERICA, INC.
2. Clean any dirt adhered to the input shaft.
3. Remove the dust cover (a).
  CAUTION:
  - Pay attention not to scratch the housing or input shaft and not to allow foreign matter to enter gearbox interior.
  - Roll a vinyl tape around the input shaft spline to avoid scratching the dust cover.
  Fig 8: Identifying Dust Cover
  Courtesy of SUBARU OF AMERICA, INC.
4. Align the ST pin with plug hole to install, and then rotate the ST counterclockwise to remove plug (b).
  PREPARATION TOOL:
  
  ST: PLUG-WRENCH (34199AE090)
  
  Fig 9: Removing Plug Using ST
  Courtesy of SUBARU OF AMERICA, INC.
5. Remove the valve assembly (c).
  CAUTION: Be careful not to scratch the seal rings (d) and inner surface of the valve housing.
  
  Fig 10: Removing Valve Assembly
  Courtesy of SUBARU OF AMERICA, INC.
Remove the rack.
1. Remove the holder (a).
  
  Fig 11: Identifying Rack Holder
  Courtesy of SUBARU OF AMERICA, INC.
2. Attach the ST1 to the pinion housing side of the rack.
3. Push the rack so that the rack piston (b) pushes out the outer side oil seal (a) to be removed.
  PREPARATION TOOL:
  
  ST1: INSTALLER & REMOVER (34199FE000)
  
  Fig 12: Removing Oil Seal Using ST
  Courtesy of SUBARU OF AMERICA, INC.
  
  NOTE: Block the pipe connection of steering body to prevent fluid from flowing out.
4. Insert the ST2 from the valve side of the rack, and push out the back-up ring (c) and oil seal (d).
  PREPARATION TOOL:
  
  ST2: REMOVER (34199FE010)
  
  Fig 13: Pushing Out Back-Up Ring And Oil Seal Using ST
  Courtesy of SUBARU OF AMERICA, INC.
  
  NOTE: Block the pipe connection of steering body to prevent fluid from flowing out.
Repair the crimped portion of cylinder.
1. Using ST, repair the crimped portion of cylinder (a).
  PREPARATION TOOL:
  
  ST1: PUNCH (34099FA080)
  
  ST2: BASE (34199FE020)
  
  Fig 14: Repairing Crimped Portion Of Cylinder Using ST
  Courtesy of SUBARU OF AMERICA, INC.
2. If the cylinder edge is deformed in a convex shape, repair using an oil stone.
  
  Fig 15: Identifying Cylinder Edge Deformed
  Courtesy of SUBARU OF AMERICA, INC.
Using the ST, press the oil seal (a) out of plug.
CAUTION: Do not apply force on the plug edge surface.

PREPARATION TOOL:

ST: OIL SEAL PLUG REMOVER (34199AE100)

Fig 16: Pressing Oil Seal Out Of Plug Using ST
Courtesy of SUBARU OF AMERICA, INC.
Remove the oil seal from the valve housing.
1. Set the ST at a size shown in the figure.
  PREPARATION TOOL:
  
  ST: GEARBOX OIL SEAL REMOVER (34199AE120)
  
  Fig 17: Identifying ST - Gearbox Oil Seal Remover
  Courtesy of SUBARU OF AMERICA, INC.
2. Set the stopper (b) to gearbox, then insert the tip of the ST to the gearbox.
  
  Fig 18: Inserting Tip Of ST To Gearbox
  Courtesy of SUBARU OF AMERICA, INC.
3. By fixing section (A), press-in the rod (c) while rotating it and catch the oil seal (a).
4. While fixing section (A), pull out the oil seal (a) by rotating nut (d).
  CAUTION: Take care not to scratch the gearbox inner surface.
  
  Fig 19: Pulling Out Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.