Control Valve Assembly

Specified steering grease: 

VALIANT GREASE M2 

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 Fluid Applying Area On Inner Wall Of Valve Housing

   Courtesy of SUBARU OF AMERICA, INC.
3. Apply grease to the oil seal.
4. Verify the direction of oil seal.
5. Using the ST and a press, install the oil seal and the bushing in valve housing.

   ST 34199AG090 INSTALLER & REMOVER

   Fig 2: Installing Oil Seal And Bushing In Valve Housing Using Special Tool And Press

   Courtesy of SUBARU OF AMERICA, INC.
6. Apply vinyl tape to the groove of pinion.
7. Install the wave washer and oil seal to pinion, and then remove the vinyl tape.
   Fig 3: Identifying Oil Seal, Vinyl Tape And Wave Washer

   Courtesy of SUBARU OF AMERICA, INC.
8. Attach the ST to pinion, and install the seal ring and O-ring.

   ST 34199AG020 GUIDE

   Fig 4: Identifying Special Tool Attached To Piston

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9. Remove the ST GUIDE, and form the seal ring properly using ST FORMER.

   ST 34199AG070 FORMER

   Fig 5: Removing Special Tool Guide

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10. Put vinyl tape around pinion shaft spline to protect oil seal from damage.
11. Install the valve to pinion, and install the snap ring.
    Fig 6: Identifying Snap Ring And Valve

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12. Attach the pinion & valve assembly into the valve housing.
    Fig 7: Identifying Valve Housing, Pinion And Valve Assembly

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13. Using a press, push the outer race of bearing and press-fit the pinion & valve assembly into housing.
    Fig 8: Pressing-Fit Pinion And Valve Assembly Into Housing Using Press

    Courtesy of SUBARU OF AMERICA, INC.
14. Apply the specified grease to dust cover.
15. Install the dust cover on valve assembly.
    CAUTION: Be sure to install the dust cover to groove of shaft.
    Fig 9: Installing Dust Cover To Groove Of Shaft

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16. Apply the genuine grease to the pinion gear and bearing of valve assembly.
    Fig 10: Applying Grease To Pinion Gear And Bearing Of Valve Assembly

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17. Install new O-ring to valve assembly.
    Fig 11: Identifying Valve Assembly O-Ring

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18. Insert the valve assembly into place while facing the rack teeth toward pinion.
    Fig 12: Removing/Installing Valve Assembly

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19. Tighten the bolts alternately to secure the valve assembly.
    CAUTION: Be sure to alternately tighten the bolts.

    Tightening torque: 

    20 N.m (2.0 kgf-m, 14.8 ft-lb) 

20. Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.

    Liquid gasket: 

    THREE BOND 1102 or THREE BOND 1215 

21. 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 13: Applying Grease On Sleeve, Spring And Adjusting Screw

    Courtesy of SUBARU OF AMERICA, INC.
22. Tighten the adjusting screw to the specified torque, then loosen it.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

23. Tighten the adjusting screw to the specified torque, then loosen it within 20°.

    Tightening torque: 

    5.9 N.m (0.6 kgf-m, 4.4 ft-lb) 

24. Adjust the turning resistance of gearbox so that it is within specification using adjusting screw. < Refer to TURNING RESISTANCE OF GEARBOX , INSPECTION, Steering Gearbox. >
25. 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): 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

    NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
26. Remove the gearbox from ST.

    ST1 926200000 STAND

    ST2 34199AG000 BOSS D

27. Install the four pipes on gearbox.
    1. Connect the pipes A and B to gearbox.

       Tightening torque: 

       Refer to "COMPONENT" of "General Description". < Refer to  POWER ASSISTED SYSTEM  , COMPONENT, General Description. > 

    2. Connect the feed pipe and return pipe to the gearbox.

       Tightening torque: 

       Feed pipe: 37 N.m (3.8 kgf-m, 27.3 ft-lb) 

       Return pipe: 29 N.m (3.0 kgf-m, 21.4 ft-lb) 

       Fig 14: Identifying Gearbox Feed And Return Pipe

       Courtesy of SUBARU OF AMERICA, INC.