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Home › Subaru › 2003 › Outback Base, 4D Sedan › Repair and Diagnosis › Steering › Power Steering › Power Assisted System (Power Steering) › Steering Gearbox › Assembly › Rack Housing Assembly

Rack Housing Assembly

CAUTION: Use only SUBARU genuine grease for gearbox.

Grease: 

  1. VALIANT GREASE M2 
  2. [Part No. 003608001, net 0.5 kg (1.1 lb)] 
  1. Clean all parts and tools before reassembling.
  2. Apply grease to teeth of rack so that grease applied is about as high as teeth, and also apply a thin film of grease to sliding portion of rack shaft.
    CAUTION:
    • When moving rack to stroke end without tie-rod attached, prevent shocks from being applied at the end.
    • Do not apply grease to threaded portion at end of rack shaft.
    • Move rack shaft to stroke end two (2) or three (3) times to squeeze grease which accumulates on both ends. Remove grease to prevent it from choking air passage hole.
  3. Apply grease to sleeve insertion hole.
  4. Apply grease to dust seal insertion hole.
    CAUTION: Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged.
  5. Apply grease to sliding surface of sleeve and spring seat, then insert sleeve into pinion housing. Fit spring into sleeve screw, pack grease inside of screw, then install the screw.
    Fig 1: Applying Grease To Sliding Surface Of Sleeve & Spring Seat
    G02873844Courtesy of SUBARU OF AMERICA, INC.
  6. Force-fit oil seal using ST.
    1. ST 34199AE060 INSTALLER
    CAUTION: Be careful not to damage or scratch cylinder inner wall.
    NOTE:
    • Apply specified power steering fluid to oil seal.
    • Pay special attention not to install oil seal in wrong direction.
    • Push oil seal until the stepped portion of A contacts end face of B.
    Fig 2: Force-Fitting Oil Seal Using ST
    G02873845Courtesy of SUBARU OF AMERICA, INC.
  7. Fixing rack housing

    Fix rack housing in vise using ST.

    1. ST 926200000 STAND
    CAUTION:
    • When fixing 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 old rack housing, be sure to clean and remove rust before assembling. Check pinion housing bushing carefully.
  8. Fit 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.
    1. ST 926390001 COVER & REMOVER
    Fig 3: Fitting ST Over Toothed Portion Of Rack Assembly
    G02873846Courtesy of SUBARU OF AMERICA, INC.
  9. Apply genuine grease to teeth of thoroughly washed rack assembly, and fit ST over the toothed portion.
    CAUTION:
    • Be careful not to block air passage hole with grease. Remove excessive grease.
    • After fitting cover, check air passage hole for clogging. If clogged, open by removing grease from the hole.
    • Check rack shaft for damage.
    • Apply specified power steering fluid to this ST and surface of piston ring to prevent seal from being damaged.
  10. Insert rack assembly into rack housing from cylinder side, and remove ST after it has passed completely through oil seal.
    NOTE: Before inserting rack assembly, apply a coat of specified power steering fluid to surfaces of ST and rack piston.
    1. ST 926390001 COVER & REMOVER
  11. Fit ST1 and ST2 over the end of rack, and install rack bushing.
    1. ST1 926400000 GUIDE
    2. ST2 927660000 GUIDE
    CAUTION:
    • If burrs, or nicks are found on this guide and rack shaft portion, remove by filing.
    • Dip rack bushing in specified power steering fluid before installing, and pay attention not to damage O-ring and oil seal.
    Fig 4: Installing Rack Bushing
    G02873847Courtesy of SUBARU OF AMERICA, INC.
  12. Insert rack stopper into cylinder tube until internal groove (on cylinder side) is aligned with external groove (on rack stopper). Turn rack stopper with ST so that rack stopper hole is seen through cylinder slits.
  13. Insert rack stopper into rack housing, and wrap circlip using a sharp pointed pliers to secure rack stopper in position.
    CAUTION: Be careful not to scratch rack while winding circlip.
    NOTE: Rotate wrench another 90 to 180° after the end of circlip has been wrapped in.
    Fig 5: Wrapping Circlip Using Pliers
    G02873848Courtesy of SUBARU OF AMERICA, INC.
  14. Fit mounting rubber onto rack housing.
  15. Apply genuine grease to pinion gear and bearing of valve assembly.
    Fig 6: Applying Grease To Pinion Gear & Bearing
    G02873849Courtesy of SUBARU OF AMERICA, INC.
  16. Install gasket on valve assembly. Insert valve assembly into place while facing rack teeth toward pinion.
    CAUTION: Be sure to use a new gasket.
    NOTE: Do not allow packing to be caught when installing valve assembly.
    Fig 7: Installing Gasket On Valve Assembly
    G02873850Courtesy of SUBARU OF AMERICA, INC.
  17. Tighten 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 bolts.
  18. Install lock washers and tighten left and right tie-rods into rack ends.
    1. Tightening torque:  78 N.m (8.0kgf-m, 58 ft-lb)
    Fig 8: Tightening Left & Right Tie-Rods
    G02873851Courtesy of SUBARU OF AMERICA, INC.
  19. Bend lock washer, using chisel.
    CAUTION: Be careful not to scratch rack when bending lock washer.
    Fig 9: Bending Lock Washer Using Chisel
    G02873852Courtesy of SUBARU OF AMERICA, INC.
  20. Rack and pinion backlash adjustment
    1. Loosen adjusting screw.
    2. Rotate input shaft so that rack is in the straight ahead direction.
    3. Apply grease to sleeve.
      Fig 10: Applying Grease To Sleeve
      G02873853Courtesy of SUBARU OF AMERICA, INC.
    4. Tighten adjusting screw by two threads.
      Fig 11: Tightening Adjusting Screw
      G02873854Courtesy of SUBARU OF AMERICA, INC.
    5. Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread.
      1. Liquid packing:  THREE BOND 1141
      Fig 12: Applying Liquid Packing To Adjusting Screw Thread
      G02873855Courtesy of SUBARU OF AMERICA, INC.
    6. Tighten adjusting screw to 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) and back off 25°.
    7. Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST.
      1. ST 926230000 SPANNER
      1. Tightening torque (Lock nut):  39 N.m (4.0 kgf-m, 29 ft-lb)
    NOTE:
    • Hold adjusting screw with a wrench to prevent it from turning while tightening lock nut.
    • Make adjustment so that steering wheel can be rotated fully from lock to lock without binding.
  21. Inspect for service limit. < Ref. to SERVICE LIMIT  , INSPECTION, Steering Gearbox.> Make replacement and adjustment if necessary.
  22. Install boot to housing.
    NOTE:
    • Before installing boot, be sure to apply grease to the groove of tie-rod.
    • Install fitting portions of boots to the following portions in both sides of assembled steering gearbox.

      The groove on gearbox

      The groove on the rod

    • Make sure that boot is installed without unusual inflation or deflation.
  23. Fit clip (large) to boot, and then install boot to gearbox while holding boot flange. After installing boot, fold back boot flange to the extent that large clip cannot be seen.
    Fig 13: Fitting Clip (Large) To Boot
    G02873856Courtesy of SUBARU OF AMERICA, INC.
  24. Turn boot until it seats well on gearbox and rubber mounting, then bend boot flange back.
    Fig 14: Turning Boot Until It Seats On Gearbox & Rubber Mounting
    G02873857Courtesy of SUBARU OF AMERICA, INC.
  25. Fix boot end with clip (small).
    CAUTION: After installing, check boot end is positioned into groove on tie-rod.
    Fig 15: Fixing Boot End With Clip (Small)
    G02873858Courtesy of SUBARU OF AMERICA, INC.
  26. If tie-rod end was removed, screw in lock nut and tie-rod end to screwed portion of tie-rod, and tighten lock nut temporarily in a position as shown in figure.

    Installed tie-rod length: L 

    1. 15 mm (0.59 in) 
    NOTE: Pay attention to difference between right and left tie-rod ends.
    Fig 16: Tightening Lock Nut Temporarily
    G02873859Courtesy of SUBARU OF AMERICA, INC.
  27. Inspect gearbox as follows:

    "A" Holding tie-rod end, repeat lock to lock two or three times as quickly as possible.

    "B" Holding tie-rod end, turn it slowly at a radius one or two times as large as possible.

    After all, make sure that boot is installed in the specified position without deflation.

    Fig 17: Inspecting Gearbox
    G02873860Courtesy of SUBARU OF AMERICA, INC.
  28. Remove gearbox from ST.
    1. ST 926200000 STAND
  29. Install four pipes on gearbox.
    1. Connect pipes A and B to four pipe joints of gearbox. Connect upper pipe B first, and lower pipe A.
      1. Tightening torque:  13 N.m (1.3 kgf-m, 9.4 ft-lb)
    2. Connect pipes C and D to gearbox. Connect lower pipe C first, and upper pipe D second.
      1. Tightening torque:  15 N.m (1.5 kgf-m, 10.8 ft-lb)
Fig 18: Connecting Pipes C & D To Gearbox
G02873861Courtesy of SUBARU OF AMERICA, INC.
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