Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 576

PS-25

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

D: ASSEMBLY

1. RACK HOUSING ASSEMBLY

1) Using a press, install the bushing to gearbox in-

stallation portion.

2) Insert the ST to rack.

ST 34199AG040 GUIDE

3) Install the seal ring and O-ring to piston portion

of rack.

4) Using the ST, form the seal ring properly.

ST1 34199AG080 FORMER PISTON

ST2 34199AG060 GUIDE G (26)

5) Using the ST A and ST B, attach the oil seal to

ST C.

ST 34199FE040 INSTALLER A, B, C

• INSTALLER A: 34199FE070

• INSTALLER B: 34199FE080

• INSTALLER C: 34199FE090
NOTE:

Face the oil seal in the direction as shown in the fig-

ure.

6) 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.

(1) Seal ring
(2) Rack
(3) O-ring

(1) Seal ring
(2) Rack
(3) O-ring

PS-00519

PS-01210

ST

(1),(3)

(2)

PS-01211

(2)

(1)

ST1

ST2

(3)

(A) Oil seal

(A) Oil seal
(B) Rack

(C) Piston

ST C

ST B

ST A

(A)

PS-01000

ST C

(A)

(B)

(C)

PS-01001

PS-26

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

7) Install the back-up ring from the gear side of

rack.

8) Check the threaded end of holder and gearbox

cylinder end for burrs, damage, etc. Correct if

faulty.

9) Apply a coat of grease to the grooves in rack,

sliding surface of sleeve and sealing surface of pis-

ton. Then insert the rack into steering body from

cylinder side.

10) Temporarily tighten a new holder to the gear-

box cylinder.

11) 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)

ST 34199XA030 INSTALLER & REMOVER

12) Set the ST to the end of rack.

ST 34199XA030 INSTALLER & REMOVER

13) Using a press, press-fit until the mark on the ST

is aligned with the end surface of the holder.

14) Remove the ST and holder.

15) Insert the outer side oil seal into the rack using

the same procedure as steps 5) and 6).

ST 34199FE040 INSTALLER A, B, C

• INSTALLER A: 34199FE070

• INSTALLER B: 34199FE080

• INSTALLER C: 34199FE090

16) Put the ST and pipe through the rack, and

press-fit the outer side oil seal using a press.

ST 34199AG010 INSTALLER

17) Secure the gearbox in a vise using ST.

ST1 926200000

STAND

ST2 34199AG000 BOSS D

(1) Oil seal
(2) Back-up ring
(3) Rack

(1) 15 mm (0.59 in)
(2) Place a mark

PS-00077

PS-00851

(1)

(2)

(1) Mark
(2) Holder

(1) Pipe
(2) Outer side oil seal

(1) Clamp

PS-00522

ST

(1)

(2)

PS-00852

(1)

ST1

ST2

PS-00492

PS-27

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

18) Tighten the holder.
Tightening torque:

70 N·m (7.1 kgf-m, 51.6 ft-lb)

19) 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 gear-

box cylinder end surface.

ST1 34099FA060

PUNCH HOLDER

ST2 34199FE020

BASE

20) 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.

21) Apply the genuine grease to the edge and body

of pinion gear and bearing of valve assembly.

22) Apply grease to a new O-ring and attach it to

the valve assembly. Insert the valve assembly into

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.

23) 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)

24) 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 in-

stalling tie-rods may damage the oil seal. Al-

ways install the left and right tie-rods.

25) Apply liquid gasket to 1/3 or more of entire pe-

rimeter of adjusting screw thread.
Liquid gasket:

THREE BOND 1102 or THREE BOND 1215

(A) Holder
(B) 2 mm (0.08 in)

(1) Dust cover
(2) Groove

(A)

(B)

ST1

ST2

ST1

PS-00859

PS-01675

(1)

(2)

PS-01674

PS-01673

PS-28

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

26) Apply a coat of grease to the sliding surface of

sleeve and seating surface of spring, and then in-

sert 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.

27) Tighten the adjusting screw to the specified

torque, then loosen it.
Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

28) Tighten the adjusting screw to the specified

torque, then loosen it within 20°.
Tightening torque:

5.9 N·m (0.6 kgf-m, 4.4 ft-lb)

29) Remove the tie-rod.

30) Adjust the turning resistance of gearbox so that

it is within specification using adjusting screw.

<Ref. to PS-36, TURNING RESISTANCE OF

GEARBOX, INSPECTION, Steering Gearbox.>

31) Attach the lock nut into adjusting screw, and

while holding the adjusting screw with wrench,

tighten the lock nut using ST.

ST 926230000

SPANNER

Tightening torque (lock nut):

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.

32) Extend the rack approx. 40 mm (1.57 in) from

steering body.

33) Install the tie-rod and new lock washer into

rack.
Tightening torque:

93 N·m (9.5 kgf-m, 68.6 ft-lb)

34) Bend the lock washer and crimp it.
CAUTION:

Be careful not to scratch the rack when crimp-

ing lock washer.

(1) Sleeve
(2) Spring
(3) Adjusting screw

(2)

(1)

(3)

PS-00167

(1) Lock washer
(2) Approx. 40 mm (1.57 in)

(1) Lock washer

PS-00439

(2)

(1)

PS-00093