Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Manual Steering Gear

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REMOVAL & INSTALLATION



Justy

See Figures 1, 2 and 3

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Fig. Fig. 1: Disassemblied steering rack-Justy



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Fig. Fig. 2: Steering rack bracket retainer bolts



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Fig. Fig. 3: Slide the rack assembly through the wheelwell opening

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the cotter pins and castle nuts from the outer tie rod ends and separate the tie rod ball studs from the steering knuckles.
  8.  
  9. From inside the vehicle, remove the two pinch bolts at the upper and lower ends of the steering shaft universal joints.
  10.  
  11. Slide the universal joint up off the rack and pinion unit.
  12.  
  13. From under the vehicle remove the rack and pinion mounting bracket bolts and brackets.
  14.  
  15. Pull the rack down slightly to clear the pinion shaft past the dust boot. Once the rack is clear, pull the assembly out through the drivers side tie rod hole.
  16.  

To install:
  1. Install the rack and pinion assembly through the driver's side tie rod hole and position on the firewall.
  2.  
  3. Make sure the pinion shaft passes through the dust boot. With the rack situated on the firewall install the rack mounting brackets and bolts. Tighten the mounting bolts to 48 ft. lbs. (67 Nm).
  4.  
  5. From inside the vehicle, slide the universal joint over the pinion shaft and install the upper and lower pinch bolts. Tighten the pinch bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Connect the tie rod ends to the steering knuckles and install the castle nuts and tighten to 20 ft. lbs. (27 Nm).
  8.  
  9. Install the tire and wheel assembly.
  10.  
  11. Lower the vehicle.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Check the front end alignment and adjust as necessary.
  16.  

Sedan, Coupe, Loyale, XT, Wagon and Brat

See Figure 4

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Fig. Fig. 4: Disassemblied steering rack assembly-Sedan, Coupe, Loyale, XT, Wagon and Brat

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle on jackstands.
  4.  
  5. Remove the front wheels.
  6.  
  7. Remove the cotter pins from the outer tie rod ends and discard. Remove the castle nuts and using a suitable tool separate the tie rod ends from the steering knuckles.
  8.  
  9. Remove the pinch bolt from the tighten rod universal joint.
  10.  
  11. Loosen the exhaust manifold mounting nuts and lower the front exhaust pipe.
  12.  
  13. Remove the four rack and pinion mounting bolts.
  14.  
  15. Move the gear box toward the pinion side. When the pinion shaft comes off the rod, rotate the gearbox rearward and remove from the vehicle.
  16.  

To install:
  1. Install the rack and pinion unit from the drivers side and move it into position so the universal joint can be connected to the pinion shaft.
  2.  
  3. Position the rack and pinion unit on the crossmember and install the four mounting bolts and brackets. Tighten the mounting bolts to 44 ft. lbs. (59 Nm).
  4.  
  5. Install the universal joint pinch bolt and tighten to 17 ft. lbs. (24 Nm).
  6.  
  7. Connect the tie rod ends to the steering knuckles and install the castle nuts. Tighten the castle nuts to 20 ft. lbs. (27Nm).
  8.  
  9. Install new cotter pins.
  10.  
  11. Tighten the exhaust manifold mounting bolts.
  12.  
  13. Install the front wheels.
  14.  
  15. Lower the vehicle.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Check and adjust the front end alignment.
  20.  

 
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