Steering Gearbox: Assembly

Apply grease to the inside and outside of a new oil seal.
Steering grease:

VALIANT GREASE M2 (Part No 003608001)
Check the direction and attachment location of the oil seal. Using an ST and a press, press fit the oil seal into the gear box.
CAUTION:
- Make sure to press fit the oil seal in all the way.
- The gap between the gear box end face and the ST is to be approximately 4 mm (0.157 in) after press fitting.
ST 34199AE130 GEAR BOX OIL SEAL INSTALLER

Fig 1: Pressing Oil Seal Into Gear Box
Courtesy of SUBARU OF AMERICA, INC.
Attach the steering body to the ST as shown in the figure. Apply grease to the needle bearing.
ST1 926200000 STAND

ST2 34199AG000 BOSS D

CAUTION: Make sure that there are no problems with the needle bearing. If faulty, replace with a new steering body.

Fig 2: Attaching 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 34199FE040 INSTALLER A, B, C

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

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

Fig 4: Inserting ST A With Oil Seal Assembled From Gear Side Of Rack
Courtesy of SUBARU OF AMERICA, INC.
Install the back-up washer from the gear side of rack.

Fig 5: Installing Back-Up Washer From Gear Side Of 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. Then insert the rack into steering body from cylinder side.
Temporarily tighten the holder to gearbox cylinder.
Mark a position 9 mm (0.35 in) from the end of the ST as indicated in the figure.
ST 34199FE000 INSTALLER & REMOVER

Fig 6: Identifying Mark On ST
Courtesy of SUBARU OF AMERICA, INC.
Set the ST to the end of rack.
ST 34199FE000 INSTALLER & REMOVER
Using a press, press-fit until the mark placed on the ST is aligned to the end surface of the holder.

Fig 7: Installing ST To End Of Rack
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST and holder.
Using the same procedures as steps 4)-5), insert the outer side oil seal to the rack.
ST 34199FE040 INSTALLER A, B, C
Place ST2 through the rack, and use the press to hold the rack and ST2.
Push in the outer side oil seal until ST1 and ST2 contact each other, and the rack end face is aligned with the end face of ST2.

ST1 34199FE050 GUIDE

ST2 34199FE060 INSTALLER

Fig 8: Pushing Outer Side Oil Seal ST1 And ST2
Courtesy of SUBARU OF AMERICA, INC.
Attach a new holder on the cylinder side of the steering body.
Tightening torque:

90 N.m (9.1 kgf-m, 65.7 ft-lb)
Using the ST, crimp one location less than 3 mm (0.12 in) from the holder.
CAUTION: Be careful not to deform the holder.

ST1 34099FA060 PUNCH HOLDER

ST2 34199FE020 BASE

Fig 9: Attaching Holder On Cylinder Side Of Steering Body
Courtesy of SUBARU OF AMERICA, INC.
Wrap the serrated part of the valve assembly with vinyl tape, and apply grease to the tape surface.

Fig 10: Wrapping Serrated Part Of Valve Assembly With Vinyl Tape
Courtesy of SUBARU OF AMERICA, INC.
Apply grease to the gear teeth of the valve assembly, and while being careful not to damage the oil seals and seal rings, attach the valve assembly.

Fig 11: Identifying Seal Ring And Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Replace the O-ring for the plug periphery with a new O-ring.
Apply grease around the oil seal, and use the ST and press to insert into the plug
ST 34199AE110 OIL SEAL PLUG INSTALLER
CAUTION:
- Attach the oil seal in the correct direction.
- To avoid compression of the oil seal, pressure insert with the plug and ST separated by 1 mm (0.039 in).
Fig 12: Inserting ST Into Plug
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, attach the plug.
ST 34199AE090 PLUG WRENCH

Tightening torque:

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

Fig 13: Attaching Plug Using ST
Courtesy of SUBARU OF AMERICA, INC.
Attach the dust cover, and remove the vinyl tape.

Fig 14: Identifying Dust Cover
Courtesy of SUBARU OF AMERICA, INC.
Temporarily attach the tie-rod to the rack end, and fully stroke the rack two or three times to the left and right to properly fit the rack.
CAUTION: Moving the rack for across its full stroke without installing tie-rods may damage the oil seal. Always install the left and right tie-rods.
Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket:

THREE BOND 1141 (Part No. 004403006)

Fig 15: Applying Liquid Gasket To Entire Perimeter Of Adjusting Screw Thread
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.

Fig 16: Identifying Grease Applying Area On Surface Of Sleeve And Seating Surface Of Spring
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:

9.8 N.m (1.0 kgf-m, 7.2 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:

4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it by approximately 30°.
CAUTION: Do not loosen by more 37° or more.

Tightening torque:

4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
Remove the tie-rod.
Check for whether play and looseness is within specifications. Refer to SERVICE LIMIT , INSPECTION, Steering Gearbox .
Install the lock nut. While holding the adjusting screw with wrench, tighten the 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.
Attach the tie-rod to the rack.
Tightening torque:

90 N.m (9.1 kgf-m, 65.7 ft-lb)

NOTE: Be careful that debris, dust, and other foreign objects do not become attached to the attachment surfaces of the rack and tie-rod.
Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.
NOTE: Make sure that the boot is installed without unusual inflation or deflation.

Fig 17: Identifying Grease Applying Area On Tie-Rod Groove
Courtesy of SUBARU OF AMERICA, INC.
Using boot clamp pliers, crimp it so that the clearance of the boot band crimping section becomes 2 mm (0.08 in) or less.
NOTE: Use a new boot band.

Fig 18: Crimping Boot Clamp
Courtesy of SUBARU OF AMERICA, INC.
Fix the boot end with small clip.

Fig 19: Fixing Boot End With Small Clip
Courtesy of SUBARU OF AMERICA, INC.
After installing, check that the boot end is installed to the groove of the tie-rod.
If the tie-rod end has been removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length L:

28 mm (1.1 in)

Fig 20: Identifying Tie-Rod Length
Courtesy of SUBARU OF AMERICA, INC.
Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock several times as quickly as possible.

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

Finally, make sure that the boot is installed at the specified position without inflating.

Fig 21: Inspecting Gearbox
Courtesy of SUBARU OF AMERICA, INC.
Remove the gearbox from ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D
Attach the four pipes to the steering body and control valve housing.