Rack Housing Assembly

Using a press, install the bushing to gearbox installation portion.

Fig 1: Installing Bushing To Gearbox Installation Position
Courtesy of SUBARU OF AMERICA, INC.
Insert the ST to rack.
Preparation tool:

ST: GUIDE (34199AG040)

Fig 2: Identifying Seal Ring, Rack, O-Ring
Courtesy of SUBARU OF AMERICA, INC.
Install the seal ring and O-ring to piston portion of rack.
Using the ST, form the seal ring properly.
Preparation tool:

ST1: FORMER PISTON (34199AG080)

ST1: GUIDE G (26) (34199AG060)

Fig 3: Installing Seal Ring And O-Ring To Rack Piston Portion
Courtesy of SUBARU OF AMERICA, INC.
Using the ST-A and ST-B, attach the oil seal to ST-C.
Preparation tool:

ST-A: INSTALLER A (34199FE070)

ST-B: INSTALLER B (34199FE080)

ST-C: INSTALLER C (34199FE090)

NOTE: Face the oil seal in the direction as shown in the figure.

Fig 4: Attaching Oil Seal To ST-C
Courtesy of SUBARU OF AMERICA, INC.
Insert the ST-C with oil seal assembled from the gear side of rack. Remove the oil seal from ST-C near piston, and then remove the ST-C from rack.

Fig 5: Removing ST-C From Rack
Courtesy of SUBARU OF AMERICA, INC.
Install the back-up ring from the gear side of rack.

Fig 6: Installing Back-Up Ring From Rack Gear Side
Courtesy of SUBARU OF AMERICA, INC.
Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty.
Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Then insert the rack into steering body from cylinder side.
Temporarily tighten a new holder to the gearbox cylinder.
Put a mark at the specified position measured from the end surface of ST as shown in the figure.
Specified position:

15 mm (0.59 in)

Preparation tool:

ST: INSTALLER & REMOVER (34199XA030)

Fig 7: Identifying Punch Mark On ST
Courtesy of SUBARU OF AMERICA, INC.
Set the ST to the end of rack.
Preparation tool:

ST: INSTALLER & REMOVER (34199XA030)
Using a press, press-fit until the mark on the ST is aligned with the end surface of the holder.

Fig 8: Pressing Holder End Surface
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST and holder.
Insert the outer side oil seal into the rack using the same procedure as steps 5 and 6.
Preparation tool:

ST-A: INSTALLER A (34199FE070)

ST-B: INSTALLER B (34199FE080)

ST-C: INSTALLER C (34199FE090)
Put the ST and pipe through the rack, and press-fit the outer side oil seal using a press.
Preparation tool:

ST: INSTALLER (34199AG010)

Fig 9: Inserting Outer Side Oil Seal Into Rack
Courtesy of SUBARU OF AMERICA, INC.
Secure the gearbox in a vise using ST.
Preparation tool:

ST1: STAND (926200000)

ST2: BOSS D (34199AG000)

Fig 10: Securing Gearbox In Vise Using ST
Courtesy of SUBARU OF AMERICA, INC.
Tighten the holder.
Tightening torque:

70 N.m (7.1 kgf-m, 51.6 ft-lb)
Using the ST, crimp so that the diameter of punch hole is 2 - 2.5 mm (0.08 - 0.10 in) and is aligned to the position of 2 mm (0.08 in) from gearbox cylinder end surface.
Preparation tool:

ST1: PUNCH HOLDER (34099FA060)

ST2: BASE (34199FE020)

Fig 11: Crimping Punch Hole Diameter
Courtesy of SUBARU OF AMERICA, INC.
Put a vinyl tape around the spline portion and apply genuine grease to the dust cover and fill it to the clearance between pinion shaft and housing, then install the valve assembly.
CAUTION: Be sure to install the dust cover to groove of shaft.

Fig 12: Installing Dust Cover To Shaft Groove
Courtesy of SUBARU OF AMERICA, INC.
Apply the genuine grease to the edge and body of pinion gear and bearing of valve assembly.

Fig 13: Applying Genuine Grease To Pinion Gear Body
Courtesy of SUBARU OF AMERICA, INC.
Apply grease to a new O-ring and attach it to the valve assembly. Insert the valve assembly into the given place while facing the rack teeth toward pinion.
CAUTION: Check that the needle bearing is not damaged. Replace with a new steering gearbox if damage is found.

Fig 14: Identifying Grease Applying Area On Valve Assembly O-Ring
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts alternately to secure the valve assembly.
CAUTION: Be sure to alternately tighten the bolts.

Tightening torque:

20 N.m (2.0 kgf-m, 14.8 ft-lb)
Temporarily tighten the tie-rod to the rack end, and then operate the rack from lock to lock for two or three times to make it fit in.
CAUTION: Operating the rack from lock to lock without installing tie-rods may damage the oil seal. Always install the left and right tie-rods.
Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket:

THREE BOND 1102
Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.

Fig 15: Identifying Grease Applying Area On Sleeve, Spring, Adjusting Screw
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it 5°.
Tightening torque:

5.9 N.m (0.6 kgf-m, 4.4 ft-lb)
Remove the tie-rod.
Adjust the turning resistance of gearbox so that it is within specification using adjusting screw. <Ref. to LIMIT , INSPECTION, Steering Gearbox.>
Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.
Preparation tool:

ST: SPANNER (926230000)

Tightening torque:

25 N.m (2.5 kgf-m, 18.4 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) from steering body.
Install the tie-rod and new lock washer into rack.
Tightening torque:

93 N.m (9.5 kgf-m, 68.6 ft-lb)

Fig 16: Identifying Tie-Rod Dimension
Courtesy of SUBARU OF AMERICA, INC.
Bend the lock washer and crimp it.
CAUTION: Be careful not to scratch the rack when crimping lock washer.

Fig 17: 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 the housing.
CAUTION: Right side boot has groove for identification, be sure to install the right and left of boot.

Fig 18: Identifying Right Side Boot With Groove
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Make sure that the boot is installed without unusual inflation or deflation.

Fig 19: Identifying Grease Applying Area On Boot
Courtesy of SUBARU OF AMERICA, INC.
Install a new boot band. Using band clamp pliers, crimp it so that the clearance of crimping portion becomes 2 mm (0.079 in) or less.

Fig 20: Identifying Boot Band Gap
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Fix the boot end with small clip.

Fig 21: Fixing Boot End With Small Clip
Courtesy of SUBARU OF AMERICA, INC.
After installing, check that the boot end is installed to the groove of the tie-rod.
If the tie-rod end has been removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length L:

28 mm (1.1 in)

Fig 22: Identifying Tie-Rod Insertion Length
Courtesy of SUBARU OF AMERICA, INC.
Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock several times as quickly as possible.

"B" Holding the tie-rod end, turn it slowly at a radius several times as large as possible.

Finally, make sure that the boot is installed in the specified position without inflating.

Fig 23: Inspecting Gearbox
Courtesy of SUBARU OF AMERICA, INC.
Remove the gearbox from ST.
Preparation tool:

ST1: STAND (926200000)

ST2: BOSS D (34199AG000)
Install the four pipes on gearbox.
1. Connect the pipes A and B to the four pipe joints of gearbox.
  Tightening torque:
  
  Cylinder side: 27 N.m (2.8 kgf-m, 19.9 ft-lb)
  
  Gear housing side: 17 N.m (1.7 kgf-m, 12.5 ft-lb)
2. Connect the feed pipe and return pipe to the gearbox.
  Tightening torque:
  
  Feed pipe: 37 N.m (3.8 kgf-m, 27.3 ft-lb)
  
  Return pipe: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
Fig 24: Connecting Feed Pipe And Return Pipe To Gearbox
Courtesy of SUBARU OF AMERICA, INC.