Steering Gearbox: Assembly

Apply a coat of grease to inside and outside of new oil seal.
Specified steering grease:

One Lube MO (Part No. 003608001)
Verify the oil seal direction and installation position. Using the ST and press, press fit the oil seal to gearbox.
ST 34199AE130 GEARBOX OIL SEAL INSTALLER

Fig 1: Identifying Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Attach the steering body to ST as shown in the figure. Apply a coat of grease to needle bearing.
ST 926200000 STAND

CAUTION: Ensure the needle bearing is free from defects. If it is faulty, replace the steering body with a new one.

Fig 2: Identifying Steering Body To ST
Courtesy of SUBARU OF AMERICA, INC.
Using the ST-B and ST-C, attach the oil seal to ST-A.
ST 927490000 INSTALLER A, B, C

NOTE: Face the oil seal in direction shown in the figure.

Fig 3: Identifying Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Insert the ST-A with oil seal assembled, through gear side of rack. Remove the oil seal from ST-A near piston, and then remove the ST-A from rack.

Fig 4: Identifying ST-A With Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Install the back-up washer from gear side of rack.

Fig 5: Identifying Back-Up Washer From Gear Side Of Rack
Courtesy of SUBARU OF AMERICA, INC.
Install the ST on rack and equally apply a thin coat of grease to the rack and ST, then install the oil seal.
ST 926250000 GUIDE

CAUTION: Be careful not to scratch the oil seal lips with piston's inner ring section.

Fig 6: Installing Guide ST 926250000 On Rack
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Install the ST on end of steering body cylinder. Then insert the rack into steering body from cylinder side. ST 34199AE000 GUIDE (Oil seal)
CAUTION: Do not allow grease to block the air vent hole on rack.

Fig 7: Identifying ST On End Of Steering Body Cylinder
Courtesy of SUBARU OF AMERICA, INC.
Using the press, slowly press the inner side oil seal until distance between the ST and end of rack becomes 65 mm (2.56 in).
ST 34199AE000 GUIDE (Oil seal)

CAUTION: Ensure the ST's inner wall is free of scratches. Otherwise, it may damage the oil seal during installation.

Fig 8: Identifying Oil Seal Using Guide ST 34199AE000
Courtesy of SUBARU OF AMERICA, INC.
Pass the ST2 and pipe through rack and press outer side oil seal until ST1 is in contact with ST2 using press.
ST1 34199AE000 GUIDE (Oil seal)

ST2 34199AE010 INSTALLER (Oil seal)

Fig 9: Identifying Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Install a new holder to cylinder side of steering body.
Tightening torque:

64 N.m (6.5 kgf-m, 47.0 ft-lb)

Fig 10: Installing New Holder To Cylinder Side Of Steering Body
Courtesy of SUBARU OF AMERICA, INC.
Using a press, press the ST until its groove is aligned with end of holder.
ST 34099FA030 INSTALLER & REMOVER

Fig 11: Identifying ST
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, clinch steering body cylinder at a point less than 3 mm (0.12 in) from holder.
CAUTION: Be careful not to deform the holder.
ST 34099FA060 PUNCH HOLDER

Fig 12: Clinching Steering Body Cylinder Using Punch Holder ST 34099FA060
Courtesy of SUBARU OF AMERICA, INC.
Roll the vinyl tape on serration part of valve assembly, and then apply grease on the tape surface.

Fig 13: Identifying Vinyl Tape
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of grease on the gear teeth of valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring.

Fig 14: Identifying Seal Ring And Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Apply grease on the oil seal circumference, and then press into the plug using ST and a press. Replace the plug circumference O-rings with new ones.
ST 34199AE110 OIL SEAL PLUG INSTALLER

CAUTION: Pay attention to the oil seal direction.

Fig 15: Identifying Plug
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, install the plug.
ST 34199AE090 PLUG WRENCH

Tightening torque:

64 N.m (6.5 kgf-m, 47.0 ft-lb)

Fig 16: Identifying Plug
Courtesy of SUBARU OF AMERICA, INC.
Install the dust cover. Remove the vinyl tape.

Fig 17: Installing Dust Cover
Courtesy of SUBARU OF AMERICA, INC.
Temporarily install the tie-rod to rack end, and then operate it from lock to lock two or three times to make it fit in. Remove the grease blocking air vent hole.
CAUTION: If operating the rack from lock to lock without installing tie-rod, it may damage the oil seal. Always install the tie-rods LH and RH.
Apply a coat of grease to the sliding surface of seat pad, sleeve and seating surface of spring, and then insert sleeve into steering body. Charge the adjusting screw with grease, and then insert the spring into adjusting screw and install on steering body.

Fig 18: Identifying Sleeve Into Steering Body
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to specified torque.
Tightening torque:

7.4 N.m (0.75 kgf-m, 5.4 ft-lb)

NOTE: Tighten to the specified tightening torque, and then loosen by 25°.
Remove the tie-rod.
Verify that play is within specified value. < Ref. to SERVICE LIMIT , Inspection, Steering Gearbox. >
Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of adjusting screw thread.
Liquid gasket:

THREE BOND 1141

Fig 19: Identifying Adjusting Screw
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw.
1. Tighten the adjusting screw to specified torque, and then loosen.
  Tightening torque:
  
  9.8 N.m (1.0 kgf-m, 7.2 ft-lb)
2. Tighten the adjusting screw to specified torque, and then loosen.
  Tightening torque:
  
  4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
3. Tighten the adjusting screw to specified torque, and then loosen by 26°.
  Tightening torque:
  
  4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
Install the lock nut. While holding the adjusting screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER

Tightening torque (Lock nut):

39 N.m (4.0 kgf-m, 28.9 ft-lb)

NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
Install the tie-rod into rack.
Tightening torque:

90 N.m (9.0 kgf-m, 65.1 ft-lb)

NOTE: Check the mating face of rack and tie-rod for foreign material, dirt, dust, etc. If required, clean the mating face.
Apply a coat of grease to the tie-rod groove, and then install the boot to housing.
NOTE: Make sure that the boot is installed without unusual inflation or deflation.

Fig 20: Applying Grease
Courtesy of SUBARU OF AMERICA, INC.
Caulk the boot so the space inside boot band caulking portion becomes 2 mm (0.08 in) or less.
NOTE: Use a new boot band.

Fig 21: Identifying Distance
Courtesy of SUBARU OF AMERICA, INC.
Fix the boot end with clip (small).

Fig 22: Fixing Clip
Courtesy of SUBARU OF AMERICA, INC.
After installing, check the boot end is positioned into groove on tie-rod.
If the tie-rod end was removed, screw in the lock nut and tie-rod end to screwed portion of tie-rod, and then tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length:

L 31.2 mm (1.23 in)

Fig 23: Identifying Lock Nut
Courtesy of SUBARU OF AMERICA, INC.
Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock two or three times as quickly as possible.

"B" Holding the tie-rod end, turn it slowly at a radius one or two times as large as possible.

After all, make sure that the boot is installed in specified position without deflation.

Fig 24: Inspecting Gearbox
Courtesy of SUBARU OF AMERICA, INC.
Remove the gearbox from ST.
ST 926200000 STAND