SUBARU TRIBECA 2009 1.G Service Workshop Manual

PS-21
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
11) Carefully draw out the input shaft and remove
the valve assembly.
12) Using a drill, release the caulking of holder.
CAUTION:
Make a hole of 2 mm (0.08 in) depth using a drill
with 3 mm (0.12 in) diameter.
13) Remove the holder using a 36 mm wrench or
adjustable wrench.
14) Remove the rack bushing and rack stopper
from rack assembly.
15) Remove the oil seal from rack.
16) Insert the ST from pinion housing side and re-
move the oil seal using a press.
ST 34199AE050 OIL SEAL REMOVER
17) Using a press, remove the bushing of gearbox
installation portion.
(1) Holder
PS-00117
PS-00516
PS-00512
(1)
(1) Press
(2) Oil seal
PS-00138
(2)
(1)
ST
PS-00517

PS-22
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
2. CONTROL VALVE
1) Disconnect the pipes A and B from gearbox.
2) Secure the gearbox removed from vehicle in a
vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
CAUTION:
Secure the gearbox in a vise using ST as shown
in the figure. Do not secure the gearbox without
this ST.
3) Using the ST, loosen the lock nut.
ST 926230000 SPANNER
4) Tighten the adjusting screw until it can no longer
be tightened.
5) Loosen the adjusting screw, and remove the
spring and sleeve.
6) Remove the two bolts securing valve assembly.
7) Carefully draw out the input shaft and remove
the valve assembly.
8) Put a vinyl tape around the spline portion, and
slide the dust cover to remove.
(1) Clamp
(1) Lock nut
(1) Adjusting screw
PS-00492
(1)
ST1
ST2
PS-00494
ST
(1)
PS-00495
(1)
(1) Dust cover
PS-00116
PS-00143
PS-00144
(1)

PS-23
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
9) Using a press, remove the pinion & valve as-
sembly from valve housing.
10) Using the ST and a press, remove the bushing
and oil seal from the valve housing.
ST 34199AG090 INSTALLER & REMOVER
CAUTION:
•Do not apply a force to the end surface of
valve housing.
•Do not reuse the oil seal after removal.
11) Using a snap ring pliers, remove the snap ring,
valve, oil seal and back-up washer.
CAUTION:
Be careful not to scratch the pinion & valve as-
sembly.
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 34199XA010 GUIDE 44
(1) Pinion & valve ASSY
(2) Valve housing
(3) Cloth
(1) Oil seal
(2) Bushing
(2)
(3)
(1)
PS-00149
(2)
(1)
PS-00150
ST
(1) Snap ring
(2) Valve
(3) Oil seal
(4) Back–up ring
(1) Seal ring
(2) Rack
PS-00518
(1)
(2)
(3)
(4)
PS-00519
PS-00520
ST
(1)
(2)

PS-24
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
3) Install the seal ring to piston portion of rack.
(1) Using the ST, form the seal ring properly.
ST1 34199XA020 FORMER PISTON 44
ST2 34199AG060 GUIDE G (26)
(2) Using the ST B and ST C, attach the oil seal
to ST A.
ST 927490000 INSTALLER A, B, C
NOTE:
Face the oil seal in the direction as shown in the fig-
ure.
(3) Insert the ST A with oil seal assembled from
the gear side of rack. Remove the oil seal from
ST A near piston, and then remove the ST A
from rack.
4) Install the back–up washer from the gear side of
rack.
(1) Seal ring
(2) Rack
(A) Oil seal
PS-00559
(2)(1)
ST1ST2
PS-00075
ST AST BST C
(A)
(A) Oil seal
(B) Rack
(C) Piston
(1) Oil seal
(2) Back–up washer
(3) Rack
PS-00076
ST A(A)
(B)
(C)
PS-00077

PS-25
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
5) Install the ST on rack, equally apply a thin coat of
grease to the rack and ST, and then install the oil
seal.
ST 926250000 GUIDE
CAUTION:
Be careful not to scratch the oil seal lips with
the inner ring section of piston.
6) 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.
7) Check the threaded end of holder and gearbox
cylinder end for burrs, damage, etc. Correct if
faulty.
8) Insert the ST into gearbox cylinder, and then
press-fit the oil seal.
ST 34199XA000 INSTALLER 44
9) Temporarily tighten the holder to gearbox cylin-
der.
10) Set the ST to the end of rack.
ST 34199XA030 INSTALLER & REMOVER 44
11) Using a press, press-fit until the groove of ST
are aligned to the end surface of holder.
12) Secure the gearbox in a vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
13) Tighten the holder.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
(1) Rack piston inner ring
(2) Outer side oil seal
(3) Rack
PS-00078
PS-00521
ST
(1) Groove
(2) Holder
(1) Clamp
(1) Holder
PS-00522
ST
(1)
(2)
PS-00492
(1)
ST1
ST2
PS-00512
(1)

PS-26
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
14) Using the ST, caulk 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.
ST 34099FA060 PUNCH HOLDER
15) Put a vinyl tape around the spline portion and
apply genuine grease to the dust cover and install
to valve assembly.
CAUTION:
Be sure to install the dust cover to groove of
shaft.
16) Apply the genuine grease to the pinion gear
and bearing of valve assembly.
17) Install a new gasket on valve assembly. Insert
the valve assembly into place while facing the rack
teeth toward pinion.
18) Tighten the bolts alternately to secure the valve
assembly.
Tightening torque:
20 N·m (2.0 kgf-m, 14.8 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
19) Temporarily install the tie-rod to rack end, and
then operate the rack from lock to lock for two or
three times to make it fit in. Remove any grease
blocking the air vent hole.
CAUTION:
Operating the rack from lock to lock without in-
stalling tierods may damage the oil seal. Al-
ways install the LEFT AND RIGHT tierods.
20) Apply liquid gasket to more than 1/3 of entire
perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1141
21) 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.
(1) 2 mm (0.08 in)
(2) Diameter: 2 — 2.5 mm (0.08 — 0.10 in)
(3) End of cylinder
(4) Holder
(1) Dust cover
(2) Groove
PS-00523
(1)
(2)(4)
(3)
PS-00534
(1)
(2)
PS-00165
(1) Sleeve
(2) Spring
(3) Adjusting screw
PS-00117
PS-00167
(2)
(1)
(3)

PS-27
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
22) Tighten the adjusting screw to the specified
torque.
Tightening torque:
3.9 N·m (0.4 kgf-m, 2.9 ft-lb)
23) Tighten the adjusting screw to the specified
torque, then loosen it 20°.
24) Remove the tie–rod.
25) Adjust the turning resistance of gearbox so that
it is within specification using adjusting screw.
GEARBOX, INSPECTION, Steering Gearbox.>
26) Apply liquid gasket to lock nut and install it into
adjusting screw. While holding the adjusting screw
with wrench, tighten the lock nut using ST.
Liquid gasket:
THREE BOND 1141
ST 926230000 SPANNER
Tightening torque (lock nut):
25 N·m (2.5 kgf-m, 18.1 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
27) Extend the rack approx. 40 mm (1.57 in) from
steering body.
28) Install the tie-rod and new lock washer into
rack.
Tightening torque:
130 N·m (13.3 kgf-m, 95.9 ft-lb)
29) Bend the lock washer and caulk it.
CAUTION:
Be careful not to scratch the rack when caulk-
ing lock washer.
30) 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.
(1) Lock washer
(2) Approx. 40 mm (1.57 in)
PS-00439
(2)
(1)
(1) Lock washer
(1) Right side boot
(2) Groove for identification
PS-00093
PS-00524
(2)
(1)

PS-28
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.
31) Install a new boot band. Using band clamp pli-
ers, caulk it so that the clearance of caulking por-
tion becomes 2mm (0. 079 in) or less.
32) Fix the boot end with small clip.
33) After installing, check that the boot end is in-
stalled to the groove of the tie–rod.
34) 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 po-
sition as shown in the figure.
Installed tie-rod length L:
31 mm (1.22 in)
35) Inspect the gearbox as follows:
Holding the “A” tie–rod end, repeat movement from
lock to lock two or three times as quickly as possi-
ble.
Holding the “B” tie–rod end, turn a few times as
slowly as possible.
Finally, make sure that the boot is installed in the
specified position without inflating.
36) Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
(A) Boot band
(B) Less than 2 mm (0.079 in)
PS-00194
PS-00499
(A)
(B)
(1) Clip
PS-00053
PS-00097
L
PS-00098
BA

PS-29
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
37) Install the four pipes on gearbox.
(1) Connect the pipes A and B to the four pipe
joints of gearbox.
Tightening torque:
Refer to the component parts. POWER ASSISTED SYSTEM, COMPONENT,
General Description.>
(2) Connect the pipes C and D to gearbox.
Tightening torque:
Pipe C: 37 N·m (3.8 kgf -m, 27.3 ft-lb)
Pipe D: 29 N·m (3.0 kgf-m, 21.4 ft-lb)
2. CONTROL VALVE ASSEMBLY
Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to
the inner wall of valve housing.
3) To avoid scratching the oil seal, apply a coat of
grease to the contact surface of installer and oil
seal.
4) Verify the direction of oil seal. Install the oil seal
to installer and position it to valve housing.
5) Press the oil seal into position using press.
ST 34199AG090 INSTALLER & REMOVER
6) Install the bearing to ST and position it to hous-
ing. Using the ST and a press, install the special
bearing in valve housing.
ST 34199AG090 INSTALLER & REMOVER
7) Apply vinyl tape to the groove of pinion.
(1) Pipe C
(2) Pipe D
(1) Apply fluid.
PS-00525(1)
(2)
PS-00169(1)
(1) Special bearing
(2) Oil seal
PS-00526
ST
(2)
(1)
PS-00527
ST

PS-30
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
8) Install the back-up ring and oil seal to pinion, and
then remove the vinyl tape.
9) Install the ST to pinion, and install the seal ring.
ST 34199AG020 GUIDE
10) Remove the ST GUIDE, and form the seal ring
properly using ST FORMER.
ST 34199AG070 FORMER
11) Put vinyl tape around pinion shaft spline to pro-
tect oil seal from damage.
12) Install the valve to pinion, and install the snap
ring.
13) Attach the pinion & valve assembly into the
valve housing.
14) Using a press, push the outer race of bearing
and press-fit the pinion & valve assembly into hous-
ing.
15) Apply the specified grease to dust cover.
(1) Oil seal
(2) Vinyl tape
(3) Back–up ring
(1) Seal ring
(1) Seal ring
PS-00528
(1)
(2)(3)
PS-00529
(1)
ST
PS-00530
ST
(1)
(1) Snap ring
(2) Valve
(1) Valve housing
(2) Pinion & valve ASSY
(1) Pinion & valve ASSY
(2) Bearing
(3) Housing
PS-00531
(2)
(1)
PS-00532(1)
(2)
PS-00533
(1)
(2)
(3)