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Steering Gearbox: Installation

WARNING: This page is about a different car, the 2004 Subaru Outback, 2004 Subaru Legacy, and 2004 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
    G00868009Courtesy 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
    G00868010Courtesy of SUBARU OF AMERICA, INC.
  4. Install universal joint. Refer 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.
    1. Castle nut tightening torque:  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: Connecting Tie-Rod End & Knuckle Arm
    G00868011Courtesy of SUBARU OF AMERICA, INC.
  6. Install front stabilizer to vehicle. Refer to INSTALLATION , Front Stabilizer.
  7. Install front exhaust pipe assembly. Refer to INSTALLATION , Front Exhaust Pipe.
    1. 2.5 L model < Refer to  INSTALLATION  , Front Exhaust Pipe. 
    2. 3.0 L model < Refer 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.

    Refer to POWER STEERING FLUID .

  12. Check for fluid leaks. Refer to OIL LEAKING  , 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: Tightening Lock Nut On Tie-Rod End
    G00868012Courtesy of SUBARU OF AMERICA, INC.
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