Steering: Overhaul Subaru Forester SF рестайлинг

Disassembly

Remove the three screws securing upper and lower steering column covers, and the two screws securing combination switch, then remove related parts.

Assembly

1. Insert combination switch to upper column shaft, and install lower column cover with tilt lever held in the lowered position. Then route ignition key harness and combination switch harness between column cover mounting bosses.
2. Fit upper column cover to lower column cover, and tighten combination switch and column cover.

Tightening torque: 1.2+/-0.2 N.m (0.12+/-0.02 kg-m, 0.9+/-0.1 ft-lb)

Scheme 1

1. Insert end of steering shaft into toe board grommet.
2. Tighten steering shaft mounting bolts under instrument panel. Tightening torque: 25+/-5 N.m (2.5+/-0.5 kg-m, 18.1+/-3.6 ft-lb)
3. Connect ignition and combination switch connectors under instrument panel.
4. Connect AIRBAG system connector at harness spool. NOTE: Make sure to apply double lock.
5. Install universal joint. Align bolt hole on the long yoke side of universal joint with the cutout at the serrated section of shaft end, and insert universal joint. Align bolt hole on the short yoke side of universal joint with the cutout at the serrated section of gearbox assembly. Lower universal joint completely. Temporarily tighten bolt on the short yoke side. Raise universal joint to make sure the bolt is properly passing through the cutout at the serrated section. Tighten bolt on the long yoke side, then that on the short yoke side. Tightening torque: 24+/-3 N.m (2.4+/-0.3 kg-m, 17.4+/-2.2 ft-lb) CAUTION: Make sure that universal joint bolts is tightened through notch in shaft serration. Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation. Standard clearance between gearbox to DOJ: Over 15 mm (0.59 in)
6. Install knee bolster. (Scheme 1): Installing Knee Bolster
7. Align center of roll connector. For 2000 models, see «ADJUSTMENTS»(ref-97335-S16171549182001043000000). For 2001 models, see «ADJUSTMENTS»(ref-150189-S09554246462002110500000). CAUTION: Ensure that front wheels are set in straight forward direction.
8. Set steering wheel to neutral and install it onto steering shaft. Tightening torque: 44+/-5 N.m (4.5+/-0.5 kg-m, 32.5+/-3.6 ft-lb) Column cover-to-steering wheel clearance: 2-4 mm (0.08-0.16 in) CAUTION: Insert roll connector guide pin into guide hole on lower end of surface of steering wheel to prevent damage. Draw out AIRBAG system connector, horn connector and cruise control connectors from guide hole of steering wheel lower end.
9. Install AIRBAG module to steering wheel. WARNING: Always refer to "Supplemental Restraint System" before performing the service operation. See «AIR BAG RESTRAINT SYSTEMS»(ref-150189).

Note. For disassembly and assembly of gearbox unit, see disassembly and assembly under CONTROL VALVE (POWER STEERING GEARBOX) .

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Scheme 7

1. Disconnect battery minus terminal.
2. Loosen front wheel nut.
3. Lift vehicle and remove front wheels.
4. Remove front exhaust pipe assembly. See «EXHAUST SYSTEM»(ref-176319). WARNING: Be careful, exhaust pipe is hot.
5. Using a puller, remove tie-rod end from knuckle arm after pulling off cotter pin and removing castle nut. (Scheme 2): Removing Tie-Rod End From Knuckle Arm
6. Remove jack-up plate and front stabilizer. (Scheme 3): Removing Jack-Up Plate
7. Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe. (Scheme 4): Removing One Pipe Joint At Center Of Gearbox
8. Remove lower side bolt of universal joint, then remove upper side bolt and lift the joint upward. NOTE: Place a mark on the joint and mating serration so that they can be re-installed at the original position. (Scheme 5): Removing Lower Side Bolt Of Universal Joint
9. Disconnect pipes C and D from pipe of gearbox. CAUTION: Be careful not to damage these pipes. NOTE: Disconnect upper pipe D first, and lower pipe C second. (Scheme 6): Disconnect Pipes "C" & "D" From Pipe Of Gearbox
10. Remove clamp bolts securing gearbox to crossmember, and remove gearbox. (Scheme 7): Remove Clamp Bolts Securing Gearbox To Crossmember

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Scheme 14

1. Disconnect the four pipes from gearbox.
2. Secure gearbox removed from vehicle in vice using ST. ST 926200000 STAND CAUTION: Secure the gearbox in a vice using the ST as shown. Do not attempt to secure it without this ST. (Scheme 8): Secure Gearbox In A Vice
3. Remove tie-rod end and lock nut from gearbox.
4. Remove small clip from boot using pliers, and move boot to tie-rod end side. (Scheme 9): Removing Small Clip From Boot Using Pliers
5. Using standard screwdriver, remove band from boot. (Scheme 10): Removing Band From Boot
6. Extend rack approximately 40 mm (1.57 in) out. Unlock lock wire at lock washer on each side of tie-rod end using a standard screwdriver. CAUTION: Be careful not to scratch rack surface as oil leaks may result. (Scheme 11): Unlocking Lock Wire At Lock Washer On Each Side Of Tie-Rod End Using A Standard Screwdriver
7. Using ST, loosen lock nut. ST 926230000 SPANNER (Scheme 12): Loosening Lock Nut
8. Tighten adjusting screw (1) until it no longer tightens. (Scheme 13): Tightening Adjusting Screw Until It No Longer Tightens
9. Using a wrench [32 mm (1.26 in) width across flats] or adjustable wrench, remove tie-rod. CAUTION: Check ball joint for free play, and tie-rod for bends. Replace if necessary. Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary. (Scheme 14): Removing Tie-Rod From Steering Gear
10. Loosen adjusting screw and remove spring and sleeve.

Scheme 15

1. Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary.
2. When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts. (Scheme 15): Inspection List Chart

Grease: VALIANT GREASE M2 [Part No. 003608001, net 0.5 kg (1.1 lb)]

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Scheme 27

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 or three 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. (Scheme 16): Applying Grease To Sliding Surface Of Sleeve & Spring Seat
6. Install lock washers and tighten left and right tie-rods into rack ends. On condition L: Approximately 40 mm (1.57 in). Tightening torque: 78+/-10 N.m (8.0+/-1.0 kg-m, 58+/-7 ft-lb) (Scheme 17): Identifying Distance "L"
7. Bend lock washer using a chisel. CAUTION: Be careful not to scratch rack when bending lock washer. (Scheme 18): Bending Lock Washer Using A Chisel
8. Rack and pinion backlash adjustment Loosen adjusting screw. Rotate input shaft so that rack is in the straight ahead direction. Apply grease to sleeve. (Scheme 19): Rack & Pinion Backlash Adjustment (1 Of 2) Tighten adjusting screw by the two threads. (Scheme 20): Rack & Pinion Backlash Adjustment (2 Of 2) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread. Liquid packing: THREE BOND 1141. (Scheme 21): Applying Liquid Packing To Adjusting Screw Thread Tighten adjusting screw to: 7.4 N.m (0.75 kg-m, 5.4 ft-lb) and back off 25°. Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 39+/-10 N.m (4.0+/-1.0 kg-m, 29+/-7 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.
9. Check for service limit as per article of "Service limit", see «SERVICE LIMIT»(ref-176750-S21061518682005051100000). Make replacement and adjustment if necessary.
10. 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. (Scheme 22): Applying Grease To Groove Of Tie-Rod
11. Using a screwdriver, tighten the screw until the ends "A" and "B" of the band come into contact with each other. CAUTION: Use a new band. NOTE: Always tighten the band from the underside of the gearbox. (Scheme 23): Tightening Band On Rack Boot
12. Fix boot end with clip (small). CAUTION: After installing, check boot end is positioned into groove on tie-rod. (Scheme 24): Installing Boot End Clip
13. 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: 15 mm (0.59 in) NOTE: Pay attention to difference between right and left tie-rod ends. (Scheme 25): Installed tie-rod length "L"
14. 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. (Scheme 26): Inspecting Gearbox
15. Remove gearbox from ST. ST 926200000 STAND
16. Install the four pipes on gearbox. Connect pipes A and B to the four pipe joints of gearbox. Connect upper pipe B first, and lower pipe A. Tightening torque: 13+/-3 N.m (1.3+/-0.3 kg-m, 9.4+/-2.2 ft-lb) Connect pipes C and D to gearbox. Connect lower pipe C first, and upper pipe D second. Tightening torque: 15+/-5 N.m (1.5+/-0.5 kg-m, 10.8+/-3.6 ft-lb) (Scheme 27): Connect Pipes "C" & "D" To Gearbox

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1. Insert gearbox into crossmember, being careful not to damage gearbox boot.
2. Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque. Tightening torque: 59+/-12 N.m (6.0+/-1.2 kg-m, 43+/-9 ft-lb) (Scheme 28): Installing Gear Box To Crossmember Bracket
3. How to install the joint. Push the long yoke of the joint, all the way into the serrated portion of the steering shaft, setting the bolt hole in the cutout. Then pull the short yoke all way out of the serrated portion of the gearbox, setting the bolt hole in the cutout. Insert the bolt through the short yoke, pull the joint and confirm that the bolt is on cutout of the gearbox. Fasten the short yoke side with a spring washer and bolt, then fasten the long yoke side. Tightening torque: 24+/-3 N.m (2.4+/-0.3 kg-m, 17.4+/-2.2 ft-lb) (Scheme 29): Installing Universal Joint
4. Connect tie-rod end to knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock. Castle nut tightening torque: Tighten to: 27.0+/-2.5 N.m (2.75+/-0.25 kg-m, 19.9+/-1.8 ft-lb), and tighten further within 60° until cotter pin hole is aligned with a slot in the nut CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer. (Scheme 30): Connecting Tie-Rod End To Knuckle Arm
5. Install front stabilizer to vehicle.
6. Install front exhaust pipe assembly. See «EXHAUST SYSTEM»(ref-176319).
7. Install tires.
8. Tighten wheel nuts to the specified torque. Tightening torque: 88+/-10 N.m (9.0+/-1.0 kg-m, 65+/-7 ft-lb)
9. Connect ground cable to battery.
10. Pour fluid into oil tank, and bleed air, see «POWER STEERING FLUID»(ref-176750-S17103790642005051100000).
11. Check for fluid leaks.
12. Install jack-up plate. WARNING: Be careful, exhaust manifold is hot.
13. Lower vehicle.
14. Check fluid level in oil tank.
15. After adjusting toe-in and steering angle, tighten lock nut on tie-rod end.

Tightening torque: 83+/-5 N.m (8.5+/-0.5 kg-m, 61.5+/-3.6 ft-lb)

Holding Boot To Prevent It From Being Rotated Or Twisted. Scheme 31

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1. Adjust front toe. Standard of front toe: IN 3-OUT 3 mm (IN 0.12-OUT 0.12 in) (Scheme 32): Identifying Tie-Rod Locknut
2. Adjust steering angle of wheels. Inner wheel: 34.4°+/-1.5° Outer wheel: 30.2°+/-1.5°
3. If steering wheel spokes are not horizontal when wheels are set in the straight ahead position, and error is more than 5° on the periphery of steering wheel, correctly re-install the steering wheel. (Scheme 33): Identifying Correct Steering Wheel Position (Wheels In Straight Ahead Position)
4. If steering wheel spokes are not horizontal with vehicle set in the straight ahead position after this adjustment, correct it by turning the right and left tie-rods in the same direction by the same turns. (Scheme 34): Adjusting Tie-Rods

Identifying Oil Leaking Points. Scheme 35

Note. This section focuses on the disassembly and reassembly of control valve. For the inspection and adjustment and the service procedures for associated parts, see STEERING GEARBOX (POWER STEERING SYSTEM) .

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1. Remove the two bolts securing valve assembly. (Scheme 36): Removing Valve Assembly
2. Carefully draw out input shaft and remove valve assembly. (Scheme 37): Removing Input Shaft & Remove Valve Assembly
3. Slide dust cover out. (Scheme 38): Sliding Off Dust Cover
4. Using a press remove pinion and valve assembly from valve housing. (Scheme 39): Removing Pinion & Valve Assembly From Valve Housing

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Scheme 41

1. Using a sharp pointed pliers, rotate the rack stopper in the direction of the arrow until the end of the circlip comes out of the stopper. Rotate the circlip in the opposite direction and pull it out. (Scheme 40): Removing Rack Stopper
2. Pull rack assembly from cylinder side, and draw out rack bushing and rack stopper together with rack assembly. CAUTION: Be careful not to contact rack to inner wall of cylinder when drawing out. Any scratch on cylinder inner wall will cause oil leakage. (Scheme 41): Pulling Rack Assembly From Cylinder
3. Remove rack bushing and rack stopper from rack assembly. CAUTION: Do not reuse removed rack bushing and circlip.

Rack Assembly

Specified grease for gearbox: VALIANT GREASE M2 (Part No. 003608001)

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Scheme 44

1. Fix rack housing in vice using ST. ST 926200000 STAND CAUTION: When fixing rack housing in vice, be sure to use this special tool. Do not fix rack housing in vice 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.
2. 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. ST 926390001 COVER and REMOVER (Scheme 42): Checking Rack Assembly For Binding Or Any Deformation, Using (ST)
3. 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 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.
4. 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. ST 926390001 COVER AND REMOVER
5. Fit ST1 and ST2 over the end of rack, and install rack bushing. ST1 926400000 GUIDE 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 seal. (Scheme 43): Installing Rack Bushing
6. 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.
7. 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. (Scheme 44): Installing Rack Stopper & Circlip
8. Fit mounting rubber onto rack housing.

Valve Assembly

Specified grease for gearbox: VALIANT GREASE M2 (Part No. 003608001)

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1. Apply specified grease to dust cover. (Scheme 45): Applying Grease To Dust Cover
2. Install dust cover on valve assembly.
3. Apply genuine grease to pinion gear and bearing of valve assembly. (Scheme 46): Applying Grease To Pinion Gear & Bearing
4. 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. (Scheme 47): Installing Valve Assembly
5. Tighten bolts alternately to secure valve assembly. Tightening torque: 25+/-5 N.m (2.5+/-0.5 kg-m, 18.1+/-3.6 ft-lb) CAUTION: Be sure to alternately tighten bolts.

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1. Disconnect battery minus terminal.
2. Lift vehicle and remove jack-up plate. (Scheme 48): Removing Jack-Up Plate
3. Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe. CAUTION: Improper removal and installation of parts often causes fluid leak trouble. To prevent this, clean the surrounding portions before disassembly and reassembly, and pay special attention to keep dirt and other foreign matter from mating surfaces. (Scheme 49): Removing Pipe Joint At Center Of Gearbox, Discharge Fluid By Turning Wheel
4. Remove clamp E from pipes C and D. (Scheme 50): Identifying Clamp "E"
5. Disconnect pipe C from pipe (on the gearbox side). CAUTION: When disconnecting pipe C, use two wrenches to prevent deformities. Be careful to keep pipe connections free from foreign matter. (Scheme 51): Identifying Pipe "C" At Gearbox
6. Remove bolt A. Disconnect pipe C from oil pump. Disconnect pipe D from oil tank. CAUTION: Do not allow fluid from the hose end to come into contact with pulley belt. To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. (Scheme 52): Identifying Bolt A, Pipe "C" & Pipe "D" At Oil Tank