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Steering Gearbox: Installation

WARNING: This page is about a different car, the 2003 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.
  1. Insert the gearbox into crossmember, being careful not to damage the gearbox boot.
  2. Tighten the gearbox to crossmember bracket via clamp with bolt to specified torque.
    1. Tightening torque:  59 N.m (6.0 kgf-m, 43.4 ft-lb)
    Fig 1: Tightening Gearbox To Crossmember Bracket Via Clamp With Bolt
    G02097247Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the pipe D first to gear box, and pipe C second.

    Tightening torque: 

    1. T:  15 N.m (1.5 kgf-m, 10.8 ft-lb)
    Fig 2: Connecting Pipe D First To Gear Box
    G02097248Courtesy of SUBARU OF AMERICA, INC.
  4. Install the universal joint. Refer to INSTALLATION  , Universal Joint.
  5. Connect the tie-rod end and knuckle arm, and tighten with castle nut.
    1. Castle nut tightening torque:  27 N.m (2.75 kgf-m, 19.9 ft-lb)
    CAUTION: When connecting, do not hit the cap at bottom of tie-rod end with hammer.
  6. After tightening the castle nut to specified torque, tighten it further within 60° until cotter pin hole is aligned with the slot in nut, and then bend the cotter pin to lock.
    Fig 3: Bending Cotter Pin To Lock
    G02097249Courtesy of SUBARU OF AMERICA, INC.
  7. Install the front stabilizer to vehicle. Refer to INSTALLATION , Front Stabilizer.
  8. Install the front exhaust pipe assembly. Refer to INSTALLATION , Front Exhaust Pipe.
  9. Install the sub frame. Refer to INSTALLATION , Sub Frame.
  10. Install the under cover. Refer to INSTALLATION , Front Under Cover.
  11. Align the center of roll connector. Refer to AIR BAG RESTRAINT SYSTEMS .
  12. Install the steering wheel. Refer to INSTALLATION  , Steering Wheel.
  13. Install the tires.
  14. Tighten the wheel nuts to specified torque.
    1. Tightening torque:  90 N.m (9.1 kgf-m, 65.8 ft-lb)
  15. Connect the battery ground cable to battery.
  16. Pour fluid into the oil tank, and bleed air. Refer to POWER STEERING FLUID  .
  17. Check for fluid leaks.
  18. Install the jack-up plate.
  19. Lower the vehicle.
  20. Check the fluid level in oil tank.
  21. After adjusting the toe-in and steering angle, tighten the lock nut on tie- rod end.
    1. Tightening torque:  83 N.m (8.5 kgf-m, 61.5 ft-lb)
NOTE: When adjusting the toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.
Fig 4: Adjusting Toe-In & Steering Angle
G02097250Courtesy of SUBARU OF AMERICA, INC.
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