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Steering Gearbox: Installation

WARNING: This page is about a different car, the 2003 Subaru Outback, 2003 Subaru Legacy, and 2003 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. Insert gearbox into crossmember, being careful not to damage gearbox boot.
  2. Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque.
    1. Tightening torque:  59 N.m (6.0 kgf-m, 43 ft-lb)
    Fig 1: Tightening Gearbox To Crossmember Bracket Via Clamp With Bolt
    G02873818Courtesy of SUBARU OF AMERICA, INC.
  3. Connect pipes C and D to pipe of gearbox.
    NOTE: Connect lower pipe C first, and upper pipe D second.
    CAUTION: Be careful not to damage these pipes.
    Fig 2: Connecting Pipes "C" & "D" To Pipe Of Gearbox
    G02873819Courtesy of SUBARU OF AMERICA, INC.
  4. Install universal joint. < Ref. to INSTALLATION  , Universal Joint.>
  5. Connect tie-rod end and knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock.

    Castle nut tightening torque: 

    1. Tighten to 27.0 N.m (2.75 kgf-m, 19.9 ft-lb), and tighten further within 60° until cotter pin hole is aligned with a slot in the nut. 
    CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.
    Fig 3: Installing Cotter Pin Into Nut
    G02873820Courtesy of SUBARU OF AMERICA, INC.
  6. Install front stabilizer to vehicle. < Ref. to INSTALLATION , Front Stabilizer.>
  7. Install front exhaust pipe assembly.

    2.5 L model 

    1. < Ref. to INSTALLATION , Front Exhaust Pipe.>

    3.0 L model 

    1. < Ref. to INSTALLATION , Front Exhaust Pipe. >
  8. Install tires.
  9. Tighten wheel nuts to the specified torque.
    1. Tightening torque:  88 N.m (9.0 kgf-m, 65 ft-lb)
  10. Connect battery ground cable.
  11. Pour fluid into oil tank, and bleed air. < Ref. to POWER STEERING FLUID  .>
  12. Check for fluid leaks. < Ref. to OIL LEAKING  , INSPECTION, Steering Gearbox.>
  13. Install jack-up plate.
    WARNING: Be careful, exhaust manifold is hot.
  14. Lower vehicle.
  15. Check fluid level in oil tank.
  16. After adjusting toe-in and steering angle, tighten lock nut on tie-rod end.
    1. Tightening torque:  83 N.m (8.5 kgf-m, 61.5 ft-lb)
    CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.
    Fig 4: Adjusting Toe-In Holding Boot
    G02873821Courtesy of SUBARU OF AMERICA, INC.
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