gearbox SUBARU TRIBECA 2009 1.G Service Workshop Manual

FS-23
Front Crossmember
FRONT SUSPENSION
8. Front Crossmember
A: REMOVAL
1) Lift-up the vehicle, and then remove the front
wheels.
2) Remove the front exhaust pipe.
3) Remove the front crossmember support plate.
Support Plate.>
4) Remove the front stabilizer. MOVAL, Front Stabilizer.>
5) Disconnect the tie-rod end from housing.
6) Remove the front arm. AL, Front Arm.>
7) Remove the nuts attaching the engine mount
cushion rubber to crossmember.
8) Remove the steering universal joint.
9) Disconnect the power steering hose from steer-
ing gearbox.
10) Lift the engine approx. 10 mm (0.39 in) using
the chain block.
11) Support the crossmember with a jack, remove
the bolts securing crossmember to body, and then
gradually lower the crossmember with steering
gearbox as a unit.
CAUTION:
When removing the crossmember downward,
be careful that the tie-rod end does not interfere
with drive shaft boot.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
•Use a new bolt and self-locking nut. For parts
which are not reusable, refer to “COMPONENT”.
tion.>
•Always tighten the stabilizer bushing in the state
where the vehicle is at curb weight and the wheels
are in full contact with the ground.
Tightening torque:
Crossmember to body:
95 N·m (9.7 kgf-m, 70.1 ft-lb)
Engine mounting to Crossmember:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
Front arm to Crossmember:
95 N·m (9.7 kgf-m, 70.1 ft-lb)
Front arm to Support plate:
145 N·m (14.8 kgf-m, 106.9 ft-lb)
Support plate to Body:
150 N·m (15.3 kgf-m, 110.6 ft-lb)
Tie–rod end to housing:
27.0 N·m (2.75 kgf-m, 19.9 ft-lb)
After tightening to the specified torque, tighten the
castle nut further but within 60° until the hole in the
ball stud is aligned with a slot in castle nut
Universal joint:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
Stabilizer clamp
25 N·m (2.5 kgf-m, 18.1 ft-lb)
Stabilizer link:
60 N·m (6.1 kgf-m, 44.3 ft-lb)
Power steering hose to Steering gearbox:
15 N·m (1.5 kgf-m, 11 ft-lb)
2) Purge air from the power steering system.
3) Inspect the wheel alignment and adjust if neces-
sary.
C: INSPECTION
Check the crossmember for wear, damage or
cracks, and then repair or replace if faulty.
FS-00209
FS-00119

PS-2
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
1. General Description
A: SPECIFICATION
Whole system
Minimum turning radius m (ft) 5.7 (18.7)
Steering angleInner wheel 37.0°±1.5°
Outer wheel 32.0°±1.5
Steering wheel diameter mm (in) 375 (14.76)
Lock to lock turn 3.44
Gearbox
Ty p e R a c k a n d P i n i o n , I n t e g r a l
Backlash 0 (Automatic adjusting)
Va l ve ( Po w e r s t e e r i n g s y s t e m ) R o t a r y va l ve
Pump
(Power steering
system)
Ty p e Va n e p u m p
Oil tank Installed on body
Specific outputcm3 (cu in)/rev.9.6 (0.586)
Relief pressurekPa (kg/cm2, psi)8,800 — 9,400 (90 — 96, 1,276 — 1,363)
Hydraulic fluid control Engine RPM sensitive
Hydraulic fluid2(US qt, Imp qt)1,000 rpm: 7.0 (7.4, 6.2)
3,000 rpm: 6.0 (6.3, 5.3)
RPM Range rpm 500 — 8,600
Direction of rotation Clockwise
Hydraulic oil
(Power steering
system)
Description ATF DEXRON III or equivalent
Capacity
2(US qt, Imp qt)
Oil tank 0.2 (0.2, 0.2)
Whole system 0.9 (1.0, 0.8)
Steering wheel Free play mm (in) 17 (0.67)
Steering shaftClearance between the steering wheel and
column covermm (in) 3.0 (0.12)
Steering gear-
box
(Power steering
system)
Sliding resistance N (kgf, lb)
400 (41, 90) or less
Difference between right and left sliding resistance:
Less than 20%
Rack shaft play in
the radial direction
Right–turn steering mm (in) 0.19 (0.0075) or less
Left–turn steering mm (in)Horizontal movement: 0.6 (0.024) or less
Ve r t i c a l m o v e m e n t : 0 . 4 ( 0 . 0 1 6 ) o r l e s s
Input shaft playIn radial direction mm (in) 0.18 (0.0071) or less
In axial direction mm (in) 0.27 (0.0106) or less
Rotation resistance N (kgf, lb)
Maximum allowable value: 10.5 (1.07, 2.36) or less
Difference between right and left sliding resistance:
Less than 20%
Oil Pump
(Power steering
system)
Pulley shaftRadial play mm (in) 0.2 (0.008) or less
Axial play mm (in) 0.6 (0.024) or less
PulleyDitch deflection mm (in) 1.0 (0.039) or less
Rotation resistance N (kgf, lb) 9.22 (0.94, 2.07) or less
Regular pressure (Unloaded)kPa (kg/cm2, psi)981 (10, 142) or less
Steering wheel
effort (Power
steering sys-
tem)
At standstill with engine idling on paved road N (kgf, lb) 29.4 (3.0, 6.6) or less
At standstill with engine stalled on paved
roadN (kgf, lb) 294.2 (30, 66.2) or less

PS-5
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
•Gearbox
(1) Pipe C (20) Adapter (39) O–ring
(2) Pipe D (21) Clamp (40) Bracket
(3) Clamp plate (22) Cotter pin (41) Bushing
(4) Universal joint (23) Castle nut (42) Lock washer
(5) Dust seal (24) Dust cover
(6) Valve housing (25) ClipTightening torque: N·m (kgf-m, ft-lb)
(7) Gasket (26) Tie–rod endT1: 3.9 (0.4, 2.9)
(8) Oil seal (27) ClipT2: 10 (1.02, 7.4)
(9) Bushing (28) BootT3: 15 (1.5, 10.8)
(10) Seal ring (29) BandT4: 17 (1.7, 12.5)
(11) Pinion & valve ASSY (30) Tie–rodT5: 20 (2.0, 14.8)
(12) Oil seal (31) Pipe BT6: 24 (2.4, 17.4)
(13) Back–up washer (32) Pipe AT7: 25 (2.5, 18.1)
(14) Ball bearing (33) Steering bodyT8: 27 (2.75, 19.9)
(15) Snap ring (34) Oil sealT9: 29 (3.0, 21.4)
(16) Lock nut (35) Piston ringT10: 37 (3.8, 27.3)
(17) Adjusting screw (36) RackT11: 60 (6.1, 44.1)
(18) Spring (37) Rack bushingT12: 85 (8.7, 62.7)
(19) Sleeve (38) HolderT13: 130 (13.3, 95.9)
PS-00729
T11
T8
T3
T12
T8
T13
T4
T13
T12
T8
(2)
(3)
T10
T5
T9
T6
T6T2
(22)
(20)
(23)
(24)
(25)
(26)
(27)
(28)(29)
(30)
(37)
(32)
(36)
(35)
(30)
(28)
(27)
(26)
(25)
(24)
(7)
(8)
(9)
(10)
(11)
(22)(23)
(5)
(6)
(4)
(1)
(3)
(12)
(13)
(15)(42)
(38)(42)
(14)(33)
(19)(18)(17)(16)(21)
(34)
(31)(39)
(39)
T7T1
(29)
(40)
T11
(41)

PS-8
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
34099AC010 ADAPTER HOSE A Used with PRESSURE GAUGE (925711000).
34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000).
926230000 SPANNER For the lock nut when adjusting backlash of gear-
box.
34099PA100 SPANNER Used when measuring the rotating resistance of
gearbox assembly.
926420000 PLUG When fluid leaks from pinion side of gearbox
assembly, remove pipe B from valve housing,
attach this tool and check fluid leaking points.
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST34099AC010
ST34099AC020
ST-926230000
ST34099PA100
ST-926420000

PS-11
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
34199AG090 INSTALLER &
REMOVER
•Used for installing oil seal of valve housing.
•Used for installing ball bearing of valve hous-
ing.
•Used for removing oil seal and ball bearing
from valve housing.
34199XA020 FORMER PISTON
44
•Used for forming seal ring of rack.
•Used with Guide G (26)(34199AG060).
34199XA000 INSTALLER 44 Used for pressing-fit oil seal of gearbox cylinder.
34199AE020 MOUNT Used to remove the oil pump.
34199AE030 INSTALLER Used for installing the oil seal to the oil pump.
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST34199AG090
ST34199XA020
ST34199XA000
ST34199AE020
ST34199AE030

PS-13
Universal Joint
POWER ASSISTED SYSTEM (POWER STEERING)
3. Universal Joint
A: REMOVAL
1) Remove the steering wheel. MOVAL, Steering Wheel.>
2) Place alignment marks on universal joint.
3) Remove the universal joint bolt, and then re-
move the universal joint.
B: INSTALLATION
1) Align the cutout portion at serrated section of the
column shaft and yoke, then install the universal
joint into column shaft.
2) Install the universal joint to the serrations of
gearbox assembly by matching alignment marks.
3) Tighten the bolt.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
Excessively large tightening torque of univer-
sal joint bolts may lead to heavy steering wheel
operation.
Clearance between coupling of universal joint
to AT level gage:
15 mm (0.59 in) or more
4) Align the center position of the roll connector.

5) Install the steering wheel. STALLATION, Steering Wheel.>
C: INSPECTION
Check for wear, damage or any other faults. Re-
place as necessary.
Service limit:
Universal joint play: 0 mm (0 in)
Maximum swing torque: 0.3 N (0.03 kgf, 0.07
lb)
Measure the swing torque of universal joint.
Service limit:
Maximum load: 3.8 N (0.39 kgf, 0.86 lb) or less
Service limit:
Maximum load: 3.8 N (0.39 kgf, 0.86 lb) or less
PS-00731
(1) Swing torque
(2) Play
(1) Yoke (Gearbox side)
(1) Yoke (Gearbox side)
PS-00033
(1)
(2)
PS-00034
PS-00035

PS-17
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
5. Steering Gearbox
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from the battery.
3) Lift-up the vehicle, and remove the front wheels.
4) Remove the under cover. MOVAL, Front Under Cover.>
5) Remove the front exhaust pipe assembly. (Non–
turbo model) Front Exhaust Pipe.>
WARNING:
Be careful not to burn yourself because the ex-
haust pipe is hot.
6) After pulling off the cotter pin and removing the
castle nut, use a puller to remove the tie–rod end
from the knuckle arm.
7) Remove the front crossmember support plate,
jack-up plate and front stabilizer. REMOVAL, Front Stabilizer.>
8) Remove the one pipe joint at the center of the
gearbox, and connect the vinyl hose to the pipe and
the joint. Discharge the fluid by turning the steering
wheel fully clockwise and counterclockwise. Dis-
charge the fluid similarly from other pipes.
9) Remove the universal joint. MOVAL, Universal Joint.>
10) Disconnect the pipe C from pressure hose first,
then disconnect pipe D from the return hose.
(1) Castle nut
(2) Tie–rod end
(3) Knuckle arm
(1) Crossmember support plate
(2) Jack–up plate
PS-00043
(2)(1)
(1)
FS-00200
(1) Pipe A
(2) Pipe B
(1) Pipe C
(2) Pipe D
(3) Pressure hose
(4) Return hose
(2)
PS-00553
(1)
PS-00538
(4)
(3)
(2)
(1)

PS-18
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
11) Remove the gear box bracket and clamp, and
remove the gearbox.
B: INSTALLATION
1) Insert the gearbox into crossmember, being
careful not to damage gearbox boot.
2) Attach the gearbox bracket and clamp.
Tightening torque:
60 N·m (6.1 kgf-m, 44.1 ft-lb)
3) Connect the pipe D to return hose first, and the
pipe C to pressure hose second.
Tightening torque:
15 N·m (1.5 kgf -m, 10.8 ft-lb)
4) Install the universal joint. STALLATION, Universal Joint.>
5) Connect the tie–rod end and knuckle arm, and
tighten with castle nut.
Castle nut tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit the cap at the bot-
tom of tie–rod end with hammer.
(1) Bracket
(2) Clamp
(1) Bracket
(2) Clamp
PS-00735
(2)(1)
PS-00735
(2)(1)
(1) Pipe C
(2) Pipe D
(3) Pressure hose
(4) Return hose
PS-00538
(4)
(3)
(2)
(1)

PS-19
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
6) After tightening the castle nut to the specified
tightening torque, tighten it further within 60° until
the cotter pin hole is aligned with slot in the nut. Fit
the cotter pin into the nut, and then bend the pin to
lock.
7) Install the front stabilizer. STALLATION, Front Stabilizer.>
8) Install the front crossmember support plate and
jack-up plate.
9) Install the front exhaust pipe assembly. (Non–
turbo model) TION, Front Exhaust Pipe.>
10) Install the under cover. LATION, Front Under Cover.>
11) Install the front wheels.
12) Tighten the wheel nuts to the specified torque.
Tightening torque:
110 N·m (11.2 kgf-m, 81.1 ft-lb)
13) Lower the vehicle.
14) Remove the steering wheel. REMOVAL, Steering Wheel.>
15) Align the center position of the roll connector.

16) Install the steering wheel. STALLATION, Steering Wheel.>
17) Connect the ground cable to the battery.
18) Pour fluid into the oil tank, and bleed air. to PS-48, Power Steering Fluid.>
19) Check for fluid leaks.
20) Check the fluid level in oil tank.
21) After adjusting toe-in and steering angle, tight-
en the lock nut on tie-rod end.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
NOTE:
When adjusting toe-in, hold the boot as shown to
prevent it from being rotated or twisted. If it be-
comes twisted, straighten it.
C: DISASSEMBLY
1. RACK HOUSING ASSEMBLY
1) Disconnect the four pipes from gearbox.
NOTE:
Remove the pipes C and D, which are fixed to
clamp plate, as a unit.
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) Remove the tie-rod end and lock nut from gear-
box.
(A) Cotter pin
(B) Castle nut
(C) Tie–rod end
DS-00042
(C)
(B)
(A)
(1) Clamp
PS-00051
PS-00492
(1)
ST1
ST2

PS-20
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
4) Remove the small clip from the boot using pliers,
and then move the boot to tie-rod end side.
5) Using a flat tip screwdriver, remove the band
from boot.
NOTE:
Replace the boot if there is damage, cracks or de-
terioration.
6) Using the ST, loosen the lock nut.
ST 926230000 SPANNER
7) Tighten the adjusting screw until it can no longer
be tightened.
8) While securing the rack with a 22 mm wrench,
remove the tie-rod using 32 mm (1.26 in) wrench or
adjustable wrench.
9) Loosen the adjusting screw, and remove the
spring and sleeve.
10) Remove the two bolts securing valve assem-
bly.
(1) Clip
(1) Band
(1) Lock nut
PS-00053
PS-00509
(1)
PS-00494
ST
(1)
(1) Adjusting screw
(1) Holder
PS-00495
(1)
PS-00058
PS-00116