Steering Gearbox: Installation

Insert gearbox into crossmember, being careful not to damage gearbox boot.
Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque.
Tightening torque:

59 N.m (6.0 kgf-m, 43 ft-lb)

Fig 1: Inserting Gearbox Into Crossmember
Courtesy of SUBARU OF AMERICA, INC.
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 Upper & Lower Pipes
Courtesy of SUBARU OF AMERICA, INC.
Install universal joint. < Ref. to , INSTALLATION , Universal Joint. >
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:

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 And Knuckle Arm
Courtesy of SUBARU OF AMERICA, INC.
Install front stabilizer to vehicle. < Ref. to INSTALLATION , Front Stabilizer . >
Install front exhaust pipe assembly. < Ref. to INSTALLATION , Front Exhaust Pipe . >
Install tires.
Tighten wheel nuts to the specified torque.
Tightening torque:

88 N.m (9.0 kgf-m, 65 ft-lb)
Connect battery ground cable.
Pour fluid into oil tank, and bleed air.
< Ref. to , POWER STEERING FLUID . >
Check for fluid leaks. < Ref. to , BASIC INSPECTION , INSPECTION, Steering Gearbox. >
Install jack-up plate.
WARNING: Be careful, exhaust manifold is hot.
Lower vehicle.
Check fluid level in oil tank.
After adjusting toe-in and steering angle, tighten lock nut on tie-rod end.
Tightening torque:

83 N.m (8.5 kgf-m, 61.5 ft-lb)

CAUTION: When adjusting toe-in, hold boot as shown in Fig 4to prevent it from being rotated or twisted. If twisted, straighten it.

Fig 4: Adjusting Toe-In While Holding Boot
Courtesy of SUBARU OF AMERICA, INC.