Steering Gearbox: Assembly

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

VALIANT GREASE M2 (Part No. 003608001)
Verify the direction of the oil seal and installation position. Using the ST and a press, press-fit the oil seal into the gearbox.
CAUTION:
- Make sure to press fit the oil seal in all the way.
- The gap between the gearbox end face and the ST is to be approximately 4 mm (0.157 in) after press fitting.
ST 34199AE130 GEARBOX OIL SEAL INSTALLER

Fig 1: Pressing Oil Seal Into Gearbox
Courtesy of SUBARU OF AMERICA, INC.
Attach the steering body to ST as shown in the illustration. Apply a coat of grease to needle bearing.
CAUTION: Make sure the needle bearing is free from defects. If it is faulty, replace the steering body with a new part.

ST1 926200000 STAND

ST2 34199AG000 BOSS D

Fig 2: Attaching Steering Body To ST
Courtesy of SUBARU OF AMERICA, INC.
Using the ST A and ST B, attach the oil seal to ST C.
ST 34199FE040 INSTALLER A, B, C
- INSTALLER A: 34199FE070
- INSTALLER B: 34199FE080
- INSTALLER C: 34199FE090
  NOTE: Face the oil seal in the direction as shown in the illustration.
  
  Fig 3: Attaching Oil Seal To ST
  Courtesy of SUBARU OF AMERICA, INC.
Insert the ST C with oil seal assembled from the gear side of rack. Remove the oil seal from ST C near piston, and then remove the ST C from rack.

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

Fig 5: Oil Seal, Back-Up Washer And 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.
Put a mark on a location of 9 mm (0.35 in) from the ST end surface as shown in the illustration.
ST 34199FE000 INSTALLER & REMOVER

Fig 6: Mark On Tool
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 on the ST is aligned with the end surface of the holder.

Fig 7: Pressing ST To End Surface Of Holder
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST and holder.
Insert the outer side oil seal into the rack using the same procedure as steps 4) and 5).
ST 34199FE040 INSTALLER A, B, C
- INSTALLER A: 34199FE070
- INSTALLER B: 34199FE080
- INSTALLER C: 34199FE090
Make the ST2 pass through the rack, and then press in the rack and ST2 using a press.
Press in the outer side oil seal until the ST1 and ST2 comes into contact with each other and the rack end surface is aligned to the end surface of the ST2.

ST1 34199FE050 GUIDE

ST2 34199FE060 INSTALLER

Fig 8: Pressing Outer Side Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Install a new holder to the cylinder side of steering body.
Tightening torque:

75 N.m (7.65 kgf-m, 55.3 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: Crimping Holder
Courtesy of SUBARU OF AMERICA, INC.
Roll a vinyl tape on the serration portion of valve assembly, and then apply grease on the tape surface.

Fig 10: Vinyl Tape Applying Area On Serration Portion Of Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Apply a coat of grease on the gear teeth of the valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring.

Fig 11: Seal Ring And Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Replace the O-rings of plug circumference with new O-rings.
Apply grease on the oil seal circumference, and then press it into the plug using ST and a press.
CAUTION:
- Install the oil seal paying attention to correct direction.
- Make sure to press fit the oil seal in all the way.
- The gap between the plug and the ST is to be approximately 1 mm (0.039 in) after press fitting.
ST 34199AE110 OIL SEAL PLUG INSTALLER

Fig 12: Gap Between Plug And ST
Courtesy of SUBARU OF AMERICA, INC.
Attach the plug using ST.
ST 34199AE090 PLUG WRENCH

Tightening torque:

64 N.m (6.53 kgf-m, 47.2 ft-lb)

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

Fig 14: Dust Cover
Courtesy of SUBARU OF AMERICA, INC.
Temporarily tighten the tie-rod to the rack end, and then operate the rack from lock to lock for two or three times to make it fit in.
CAUTION: If operating the rack from lock to lock without installing tie-rods, it may damage the oil seal. Always install the tie-rods LH and RH.
Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket:

THREE BOND 1102 or THREE BOND 1215

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: Applying Grease To Sliding 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 (0.99 kgf-m, 7.2 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:

4.9 N.m (0.49 kgf-m, 3.6 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it approx. 30°.
CAUTION: Do not loosen 37° or more.

Tightening torque:

4.9 N.m (0.49 kgf-m, 3.6 ft-lb)
Remove the tie-rod.
Adjust the turning resistance of gearbox so that it is within specification using adjusting screw. < Ref. to SERVICE LIMIT , INSPECTION, Steering Gearbox. >
Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.
ST 926230000 SPANNER

Tightening torque (lock nut):

39 N.m (3.98 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 (9.18 kgf-m, 66.4 ft-lb)

NOTE: Check the mating face of rack and tie-rod for foreign matter such as dust etc.
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: Grease Applying Area On Tie-Rod Groove
Courtesy of SUBARU OF AMERICA, INC.
Using the boot clamp pliers, crimp the boot so that the clearance of the boot band crimp portion becomes 2 mm (0.08 in) or less.
NOTE: Use a new boot band.

Fig 18: Installing Boot Band Using Boot Clamp Pliers
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 illustration.
Installed tie-rod length L:

28 mm (1.1 in)

Fig 20: Installed 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 in 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 4 pipes to the steering body and control valve housing.