Subaru Forester 1998-05

Removal & Installation

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Click image to see an enlarged view

Fig. Exploded view of the rack and pinion steering gear

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Engine undercover
     

  4.  
  5. Remove the sub frame while referring to the accompanying illustrations for bolt locations as follows:
    1. Loosen bolt (1) but leave it connected by a few threads.
    2.  
    3. Remove bolts 2, 3, 4, 5 and 6 (in that order) and remove the subframe.
    4.  



    Click image to see an enlarged view

    Fig. Remove the sub frame bolts in the sequence illustrated following the procedure specified in the text



    Y-pipe
     
    Tie rod end cotter pin and nut
     
    Jack-up plate and front sway bar
     
    Fluid lines from the rack and pinion
     

  6.  
  7. Matchmark the universal joint to the serration in the steering rack for installation reference.
  8.  
  9. Remove or disconnect the following:

    Universal joint bolts and lift the joint upward disconnecting it from the rack and pinion shaft.
     
    Rack and pinion
     

  10.  

To install:

  1. Install the rack and pinion. Torque the clamp bolts to 43 ft. lbs. (59 Nm).
  2.  
  3. Align the steering rack to the universal joint. Push the long yoke of the joint all the way into the serrated position of the steering shaft, setting the bolt hole in the cut-out. Pull the short yoke all the way out of the serrated portion of the rack and pinion, setting the bolt hole in the cut-out. Insert the bolt through the short yoke. Pull the yoke and ensure the bolt is properly engaged in the cut-out. Fasten the short yoke side with the spring washer and bolt, then fasten the yoke side. Tighten the bolts to 17 ft. lbs. (24 Nm).
  4.  
  5. Install or connect the following:

    Tie rod ends to the steering knuckle
     
    Sway bar and jack-up plate
     
    Y-pipe with new gaskets and nuts
     

  6.  
  7. Install the sub frame while referring to the accompanying illustrations for bolt locations as follows:
    1. Replace any M12 bolts with new ones. tighten the bolts marked in the illustration as (T1) to 41 ft. lbs. (55 Nm) and the bolts marked (T2) to 52 ft. lbs. (71 Nm).
    2.  
    3. Inspect all the bolts and make sure they are torqued to the proper specification.
    4.  

  8.  
  9. Install or connect the following:

    Engine undercover
     
    Wheels
     

  10.  
  11. Fill and bleed the steering system.
  12.  


    Click image to see an enlarged view

    Fig. Install the sub frame bolts and tighten to the specifications listed in the procedure


  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the front wheel nut.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the tires and wheels.
  8.  
  9. Remove the undercover.
  10.  
  11. Remove the sub frame. Leave bolt (1) connected by a few threads and remove the bolts in the sequence illustrated. Once the other bolts are removed, remove bolt (1) and the sub frame.
  12.  
  13. Remove the front exhaust pipe.
  14.  
  15. Remove the cotter pin and castle nut. Using a puller, remove the tie rod end from the knuckle arm.
  16.  
  17. Remove the jack up plate. Remove the front stabilizer.
  18.  
  19. Disconnect the power steering fluid pipe at the center of the gearbox and attach a vinyl hose. Discharge the fluid into a suitable container by turning the steering wheel fully clockwise and counterclockwise. Disconnect the other fluid line, and repeat the discharge procedure.
  20.  
  21. Remove the steering wheel. Make a matchmark on the universal joint. Remove the universal joint bolts and remove the joint from the vehicle.
  22.  
  23. Disconnect the fluid lines from the steering gear, pressure hose first.
  24.  
  25. Remove the steering gear retaining bolts and clamps securing the steering gear to the crossmember. Remove the steering gear from the vehicle.
  26.  

To install:

  1. Insert the steering gear into the crossmember. Be careful not to damage the gearbox boot.
  2.  
  3. Tighten the steering gear to the crossmember bracket to 44.1 ft. lbs.
  4.  
  5. Connect the fluid lines.
  6.  
  7. Align the cutout at the serrated section of the column shaft and yoke. Insert the universal joint into the column shaft.
  8.  
  9. Align the mating marks and insert the universal joint to serrated section of the steering gear assembly. Tighten the bolt to 17.4 ft. lbs.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. When installing the sub frame be sure to torque the bolts to specification and in the proper sequence. Tighten bolts marked (T1) to 41 ft. lbs. (55 Nm) and the bolts marked (T2) to 52 ft. lbs. (71 Nm).
  14.  
  15. Fill the power steering system with the proper grade and type fluid.
  16.  
  17. Start the engine and check for leaks. Correct as required.

    Click image to see an enlarged view

    Fig. Steering column joint alignment-2005 Models

  18.  

 
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