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Steering Gearbox: Assembly

  1. Install the tie-rod into rack.
    CAUTION: Check the mating face of rack and tie-rod for foreign matter such as dust etc.
    1. Use the ST to secure the steering rack on the LH side (width across flat portion) and install the tie-rod on the RH side.

      Preparation tool: 

      ST: VARIABLE OPEN WRENCH (09922-10010)

      Tightening torque: 

      Calculation formula

      T = 105 N.m (10.7 kgf-m, 77.4 ft-lb) x L1/(L1 + L2)

      T: Tightening torque

      L1: Effective length of the torque wrench

      L2: Effective length of the ST

      NOTE: If the effective length of the torque wrench used is unknown, consult the manufacturer of the torque wrench.
      G16526491Courtesy of SUBARU OF AMERICA, INC.
      (a) Effective length of the ST (L2)
      (b) Effective length of the torque wrench (L1)
      (c) Center of drive square of the ST
      (d) Center of drive square of the torque wrench
      (e) Center of the position where a force is applied by hand
      G16526492Courtesy of SUBARU OF AMERICA, INC.
    2. Use the ST to install the tie-rod on the LH side.

      Preparation tool: 

      ST: VARIABLE OPEN WRENCH (09922-10010)

      Tightening torque: 

    Calculation formula

    T = 105 N.m (10.7 kgf-m, 77.4 ft-lb) x L1/(L1 + L2)

    T: Tightening torque

    L1: Effective length of the torque wrench

    L2: Effective length of the ST

    NOTE: If the effective length of the torque wrench used is unknown, consult the manufacturer of the torque wrench.
    G16526491Courtesy of SUBARU OF AMERICA, INC.
    (a) Effective length of the ST (L2)
    (b) Effective length of the torque wrench (L1)
    (c) Center of drive square of the ST
    (d) Center of drive square of the torque wrench
    (e) Center of the position where a force is applied by hand
    G16526494Courtesy of SUBARU OF AMERICA, INC.
  2. Apply a coat of grease to the tie-rod groove, and then install the boot steering gearbox to the housing.
    CAUTION: Assemble the small end of the boot steering gearbox in the tie-rod groove first, and then assemble the large end of the boot steering gearbox in the housing.
    NOTE: Make sure that the boot steering gearbox is installed without unusual inflation or deflation.

    Preparation items: 

    Grease: IDEMITSU APOLLOIL AUTOLEX A, Toshiba silicone TSM650, or equivalent

    G11245605Courtesy of SUBARU OF AMERICA, INC.
  3. Using the ST, crimp the band boot so that the clearance (b) of the band boot (a) crimp portion is 2 mm (0.08 in) or less.
    NOTE: Use a new band boot.

    Preparation tool: 

    ST: BOOT BAND PLIERS (28099AC000)

    G16526496Courtesy of SUBARU OF AMERICA, INC.
  4. Fix the smaller end of the boot steering gearbox with the clip boot tie-rod (a).
  5. After installation, check that the smaller end of the boot steering gearbox is installed to the groove (b) of the tie-rod.
    G16526497Courtesy of SUBARU OF AMERICA, INC.
  6. If the tie-rod end has been removed, screw in lock nut and tie-rod end to the threaded portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.

    Installed tie-rod length: 

    L: Approx. 25 mm (0.98 in)

    G16526498Courtesy of SUBARU OF AMERICA, INC.
  7. Inspect the steering gearbox assembly as follows:
    1. "A" Holding the tie-rod end, repeat lock to lock several times as quickly as possible.
    2. "B" Holding the tie-rod end, turn it slowly at a radius several times as large as possible.
    3. Finally, make sure that the boot steering gearbox is installed in the specified position without inflating.
G05032955Courtesy of SUBARU OF AMERICA, INC.
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