Subaru 1600 Service Manual page 492

2. Removal
1) Disconnect ground cable from
battery.
2) Jack up vehicle, place safety
stands (rigid racks) under both front
lifting points, and then remove both
front wheels.
3) Pull out the cotter pin, loosen the
castle nut and remove the tie-rod end
from the knuckle arm of the housing
by using a puller etc.
In order to remove the tie-rod end
from the housing easily, apply a pen-
etrating oil (CRC, LOOSEN, SUBARU
GUARD etc.) to the tie-rod end.
4) Remove the rubber coupling con-
necting nuts and disconnect the
pinion with gearbox from the rubber
coupling.
A18·060
Fig. 1140 Removing rubber coupling
5) Loosen nuts connecting the ex-
haust manifold with engine and
pull down the exhaust manifold.
6) Remove a boot protector.
7) Remove bolts fitting the gear-
box bracket to the crossmember.
8) Pull down the steering gearbox
until pinion flange is pulled out of
the hole of crossmember. Turn gear-
box backward and pull it out toward
the left side.
NOTE:
Take care not to damage the gearbox
boot.
STEERING SYSTEM
3. Disassembly
1) Vise the gearbox.
NOTE:
When vising the gearbox, insert alu-
minum plates between the vise and
gearbox for preventing damage to the
gearbox.
Aluminum plates
A18-085
Fig. 11-41
2) Remove tie rod end and lock nut
from the tie rod.
3) Remove clips (smaller and larger
ones) on outside end of boot, and then
remove boot from steering gearbox.
NOTE:
Be careful not to damage boot with a
driver or the like when removing clips
(smaller and larger ones).
~
Clip (large)
/ 8 A
A18-126
Fig. 1142
4) Unbend the lock washer on ball
joint with slot screwdriver or chisel
etc.
5) Unscrew the ball joint and remove
the tie rod from the rack.
11-19
NOTE:
Hold the rack with a adjustable wrench
etc. to prevent it from turning.
A18-018
Fig. 1143 Removing ball joint
6) Loosen the lock nut on the gear-
box adjusting screw and unscrew
fully the adjusting screw.
1 Adjusting screw
2 Lock nut
Fig. 1144
7) Remove spring and sleeve.
A18-304
8) Detach the oil seal of pinion from
the gearbox unit with a slot screw-
driver.
NOTE:
Replace the oil seal with a new one
every disassembly.
9) Remove the snap ring (larger one)
with snap ring pliers.
NOTE:
Be careful not to damage the housing
inner face by snap ring and pliers.