Control Valve Assembly

Specified steering grease: VALIANT GREASE M2 (Part No. 003608001) 

1. Clean all parts and tools before reassembling.
2. Apply a coat of specified power steering fluid to the inner wall of valve housing.
   Fig 1: Identifying Valve Housing

   Courtesy of SUBARU OF AMERICA, INC.
3. Attach ST2 to ST1, and press the oil seal into the place using a press.

   ST1 34099FA120 INSTALLER & REMOVER

   SEAL ST2 34099FA130 INSTALLER SEAL

   1. Face oil seal in the direction shown in figure when installing.
   2. To avoid scratching oil seal, apply a coat of grease to the contact surface of installer and oil seal.
   3. To facilitate installation, attach oil seal to the installer and position in valve housing before pressing into place.
      Fig 2: Identifying Oil Seal Direction

      Courtesy of SUBARU OF AMERICA, INC.
4. Using ST and press, install the special bearing in valve housing.

   ST 34099FA120 INSTALLER & REMOVER SEAL

   NOTE: To facilitate installation, attach the ball bearing to the remover and position in valve housing before pressing it into place.
   Fig 3: Installing Special Bearing In Valve Housing

   Courtesy of SUBARU OF AMERICA, INC.
5. Put vinyl tape around pinion shaft splines to protect oil seal from damage.
6. Fit pinion and valve assembly into valve housing.
7. Secure valve assembly to ST1 and ST2.
8. Put ST3 over pinion, and insert oil seal, then force-fit oil seal into housing using ST4.

   ST1 926370000 INSTALLER A

   ST2 34099FA100 STAND BASE

   ST3 926360000 INSTALLER A

   ST4 927620000 INSTALLER B

   Fig 4: Inserting Oil Seal Into Housing

   Courtesy of SUBARU OF AMERICA, INC.
   NOTE:

   • Apply the specified power steering fluid to the oil seal and ST3, being careful not to damage oil seal lip.
   • Push the oil seal until ST3 contacts housing end face.
9. Remove ST3, and fit backing washer.
10. Force-fit ball bearing using ST3.

    ST1 926370000 INSTALLER A

    ST2 34099FA100 STAND BASE

    ST3 927640000 INSTALLER B

    Fig 5: Installing Backing Washer

    Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Be careful not to tilt ball bearing during installation.
11. Install the snap ring using snap ring pliers.
    NOTE: Rotate the snap ring to check for proper installation.
12. Apply the specified grease to the dust cover.
    Fig 6: Installing Snap Ring

    Courtesy of SUBARU OF AMERICA, INC.
13. Install the dust cover on the valve assembly.
14. Apply genuine grease to the pinion gear and bearing of valve assembly.
    Fig 7: Installing Dust Cover On Valve Assembly

    Courtesy of SUBARU OF AMERICA, INC.
15. Install the gasket on the valve assembly. Insert the valve assembly into the place while facing rack teeth toward pinion.
    CAUTION: Be sure to use a new gasket. 
    NOTE: Do not allow packing to be caught when installing valve assembly.
    Fig 8: Installing Gasket On Valve Assembly

    Courtesy of SUBARU OF AMERICA, INC.
16. Tighten the bolts alternately to secure the valve assembly.

    Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    CAUTION: Be sure to alternately tighten bolts. 
17. Apply grease to the sleeve insertion hole.
18. Apply grease to the dust seal insertion hole.
    CAUTION: Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged. 
19. Apply grease to the sliding surface of sleeve and spring seat, then insert the sleeve into the pinion housing. Fit the spring into the sleeve the screw, pack grease inside of screw, then install the screw.
    Fig 9: Applying Grease To Sliding Surface Of Sleeve & Spring Seat

    Courtesy of SUBARU OF AMERICA, INC.
20. Rack and pinion backlash adjustment
    1. Loosen the adjusting screw.
    2. Rotate the input shaft so that the rack is in the straight ahead direction.
    3. Apply grease to the sleeve.
       Fig 10: Applying Grease To Sleeve

       Courtesy of SUBARU OF AMERICA, INC.
    4. Tighten the adjusting screw by two threads.
       Fig 11: Tightening Adjusting Screw

       Courtesy of SUBARU OF AMERICA, INC.
    5. Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread.

       Liquid packing: THREE BOND 1141 

       Fig 12: Applying Liquid Packing

       Courtesy of SUBARU OF AMERICA, INC.
    6. Tighten the adjusting screw to 7.4 N.m (0.75 kgf-m, 5.4 ft-lb) and back off 25°.
    7. Install the lock nut. While holding adjusting screw with a wrench, tighten the lock nut using ST.

    ST 926230000 SPANNER

    Tightening torque (Lock nut): 39 N.m (4.0 kgf-m, 29 ft-lb) 

    NOTE:

    • Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
    • Make adjustment so that the steering wheel can be rotated fully from lock to lock without binding.
21. Check for service limit as per article of "Service limit". Refer to INSPECTION , Steering Gearbox. Make replacement and adjustment if necessary.
22. Take off the gearbox from ST.
23. Install the four pipes on the gearbox.
    1. Connect the pipe A and B to the gearbox.

       Tightening torque: 13 N.m (1.3 kgf-m, 9.4 ft-lb) 

    2. Connect the pipe E and F to the gearbox.

       Tightening torque: 

       Pipe E: 15 N.m (1.5 kgf-m, 10.8 ft-lb) 

       Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)