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Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly 2005 Subaru Forester

generation: → 2002 - 2007Release year → 2005 ✔ engine size → 2.5L ✔      add to compare      read later

POWER ASSISTED SYSTEM (POWER STEERING) > Steering Gearbox

ASSEMBLY

1. Apply a coat of grease to inside and outside of new oil seal.

Specified steering grease:

One Luber MO (Part No. 003608001)

2. Verify the oil seal direction and installation position. Using the ST and press, press fit the oil seal to gearbox.

ST    34199AE130GEARBOX OIL SEAL INSTALLER

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Oil seal

3. Attach the steering body to ST as shown in the figure. Apply a coat of grease to needle bearing.

ST    926200000STAND

CAUTION:

Ensure the needle bearing is free from defects. If it is faulty, replace the steering body with a new one.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Steering body

4. Using the ST·B and ST·C, attach the oil seal to ST·A.

ST    927490000INSTALLER A, B, C

NOTE:

Face the oil seal in direction shown in the figure.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(A)

Oil seal

5. Insert the ST·A with oil seal assembled, through gear side of rack. Remove the oil seal from ST·A near piston, and then remove the ST·A from rack.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(A)

Oil seal

(B)

Rack

(C)

Piston

6. Install the back-up washer from gear side of rack.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Oil seal

(2)

Back-up washer

(3)

Rack

7. Install the ST on rack and equally apply a thin coat of grease to the rack and ST, then install the oil seal.

ST    926250000GUIDE

CAUTION:

Be careful not to scratch the oil seal lips with piston’s inner ring section.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Rack piston inner ring

(2)

Outer side oil seal

(3)

Rack

8. Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Install the ST on end of steering body cylinder. Then insert the rack into steering body from cylinder side.

ST    34199AE000GUIDE (Oil seal)

CAUTION:

Do not allow grease to block the air vent hole on rack.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Cylinder side of steering body

(2)

Air vent hole

(3)

Oil seal

(4)

Rack

9. Using the press, slowly press the inner side oil seal until distance between the ST and end of rack becomes 65 mm (2.56 in).

ST    34199AE000GUIDE (Oil seal)

CAUTION:

Ensure the ST’s inner wall is free of scratches. Otherwise, it may damage the oil seal during installation.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Rack piston

(2)

Inner side oil seal

(3)

Back-up ring

10. Pass the ST2 and pipe through rack and press outer side oil seal until ST1 is in contact with ST2 using press.

ST1    34199AE000GUIDE (Oil seal)
ST2    34199AE010INSTALLER (Oil seal)

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Pipe

(2)

Outer side oil seal

11. Install a new holder to cylinder side of steering body.

Tightening torque:

64 N·m (6.5 kgf-m, 47.0 ft-lb)

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

12. Using a press, press the ST until its groove is aligned with end of holder.

ST    34099FA030INSTALLER & REMOVER

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Installer guide

(2)

Holder

(3)

Rack piston

(4)

Oil seal

(5)

Back-up ring

13. Using the ST, clinch steering body cylinder at a point less than 3 mm (0.12 in) from holder.

CAUTION:

Be careful not to deform the holder.

ST    34099FA060PUNCH HOLDER

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(A)

Holder

(B)

3 mm (0.12 in)

14. Roll the vinyl tape on serration part of valve assembly, and then apply grease on the tape surface.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Vinyl tape

15. Apply a coat of grease on the gear teeth of valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Seal ring

(2)

Oil seal

16. Apply grease on the oil seal circumference, and then press into the plug using ST and a press. Replace the plug circumference O-rings with new ones.

ST    34199AE110OIL SEAL PLUG INSTALLER

CAUTION:

Pay attention to the oil seal direction.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Plug

(2)

O-ring

(3)

Oil seal

17. Using the ST, install the plug.

ST    34199AE090PLUG WRENCH

Tightening torque:

64 N·m (6.5 kgf-m, 47.0 ft-lb)

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assemblyi\

(1)

Plug

18. Install the dust cover. Remove the vinyl tape.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Dust cover

19. Temporarily install the tie-rod to rack end, 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.

20. Apply a coat of grease to the sliding surface of seat pad, 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.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Seat pad

(2)

Sleeve

(3)

Spring

(4)

Adjusting screw

(5)

Lock nut

21. Tighten the adjusting screw to specified torque.

Tightening torque:

7.4 N·m (0.75 kgf-m, 5.4 ft-lb)

NOTE:

Tighten to the specified tightening torque, and then loosen by 25°.

22. Remove the tie-rod.

23. Verify that play is within specified value. POWER ASSISTED SYSTEM (POWER STEERING) > Steering Gearbox > INSPECTION

24. 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

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Apply liquid gasket to at least 1/3 of entire perimeter.

25. Tighten the adjusting screw.

(1) Tighten the adjusting screw to specified torque, and then loosen.

Tightening torque:

9.8 N·m (1.0 kgf-m, 7.2 ft-lb)

(2) Tighten the adjusting screw to specified torque, and then loosen.

Tightening torque:

4.9 N·m (0.50 kgf-m, 3.6 ft-lb)

(3) Tighten the adjusting screw to specified torque, and then loosen by 26°.

Tightening torque:

4.9 N·m (0.50 kgf-m, 3.6 ft-lb)

26. Install the lock nut. While holding the adjusting screw with a wrench, tighten lock nut using ST.

ST    926230000SPANNER

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.

27. Install the tie-rod into rack.

Tightening torque:

90 N·m (9.0 kgf-m, 65.1 ft-lb)

NOTE:

Check the mating face of rack and tie-rod for foreign material, dirt, dust, etc.

If required, clean the mating face.

28. 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.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

29. Caulk the boot so the space inside boot band caulking portion becomes 2 mm (0.08 in) or less.

NOTE:

Use a new boot band.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(A)

Boot band

(B)

Less than 2 mm (0.08 in)

30. Fix the boot end with clip (small).

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

(1)

Clip

31. After installing, check the boot end is positioned into groove on tie-rod.

32. 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

31.2 mm (1.23 in)

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

33. 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.

2005 Subaru Forester Steering • Power Assisted System (Power Steering) • Steering Gearbox • Assembly

34. Remove the gearbox from ST.

ST    926200000STAND

    2017-02-20 18:50:38    2017-06-19 10:25:05




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