Steering Gearbox: Installation

WARNING: This page is about a different car, the 2012 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

Insert the gearbox into crossmember, being careful not to damage gearbox boot.
Install the gearbox and stiffener. Temporarily tighten the bolts.

Fig 1: Locating Gearbox Bracket Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.
Insert bolts through the clamp to temporarily tighten the gearbox to the crossmember bracket.

Fig 2: Locating Gearbox Clamp Bolts
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts temporarily holding the gearbox clamp and bracket together to the specified torque.
Tightening torque:

60 N.m (6.12 kgf-m, 44.3 ft-lb)
Connect the return pipe to the return hose and then connect the feed pipe to the pressure hose.
Tightening torque:

15 N.m (1.53 kgf-m, 11.1 ft-lb)

Fig 3: Feed Pipe, Return Pipe, Pressure Hose And Return Hose
Courtesy of SUBARU OF AMERICA, INC.
Install the universal joint. < Ref. to INSTALLATION , Universal Joint. >
Connect the tie-rod end and knuckle arm, and tighten with castle nut.
CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer.

Castle nut tightening torque:

27 N.m (2.75 kgf-m, 19.9 ft-lb)
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.

Fig 4: Cotter Pin, Castle Nut And Tie-Rod End
Courtesy of SUBARU OF AMERICA, INC.
Install the front stabilizer. < Ref. to INSTALLATION , Front Stabilizer. >
Install the front crossmember support plate and jack-up plate.
Install the front exhaust pipe assembly.
- Non-turbo model: < Ref. to INSTALLATION , Front Exhaust Pipe. >
- Turbo model: < Ref. to INSTALLATION , Front Exhaust Pipe. >
Install the undercover. < Ref. to INSTALLATION , Front Under Cover. >
Install the front wheels.
Tighten the wheel nuts to the specified torque.
Tightening torque:

100 N.m (10.2 kgf-m, 73.8 ft-lb)
Lower the vehicle.
Remove the steering wheel. < Ref. to REMOVAL , Steering Wheel. >
Align the center position of the roll connector. < Ref. to ADJUSTMENT , Roll Connector. >
Install the steering wheel. < Ref. to INSTALLATION , Steering Wheel. >
Connect the battery ground terminal.
Pour fluid into the oil tank, and bleed air. < Ref. to POWER STEERING FLUID . >
Check for fluid leaks.
Check the fluid level in oil tank.
After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.
Tightening torque:

85 N.m (8.67 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 becomes twisted, straighten it.

Fig 5: Adjusting Toe-In Of Boot
Courtesy of SUBARU OF AMERICA, INC.