Rack Housing Assembly

Using a press, install the bushing to gearbox installation portion.

Fig 1: Installing Bushing To Gearbox
Courtesy of SUBARU OF AMERICA, INC.
Insert the ST to rack.
ST 34199XA010 GUIDE 44

Fig 2: Inserting ST To Rack
Courtesy of SUBARU OF AMERICA, INC.
Install the seal ring to piston portion of rack.
1. Using the ST, form the seal ring properly.
  ST1 34199XA020 FORMER PISTON 44
  
  ST2 34199AG060 GUIDE G (26)
  
  Fig 3: Installing Seal Ring Of Rack
  Courtesy of SUBARU OF AMERICA, INC.
2. 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 4: Attaching Oil Seal
  Courtesy of SUBARU OF AMERICA, INC.
3. 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 5: Removing Oil Seal Using ST
  Courtesy of SUBARU OF AMERICA, INC.
Install the back-up washer from the gear side of rack.

Fig 6: Installing Gear Side Of Rack
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 7: Attaching Oil Seal To ST
Courtesy of SUBARU OF AMERICA, INC.
Insert the ST A with oil seal assembled into the rack. Remove the oil seal from ST A near rack piston inner ring, and then remove the ST A from rack.
CAUTION: Be careful not to scratch the oil seal lips with the inner ring section of piston.

Fig 8: Inserting Oil Seal With ST
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.
Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty.
Insert the ST into gearbox cylinder, and then press-fit the oil seal.
ST 34199XA000 INSTALLER 44

Fig 9: Identifying ST Into Gearbox Cylinder
Courtesy of SUBARU OF AMERICA, INC.
Temporarily tighten the holder to gearbox cylinder.
Set the ST to the end of rack.
ST 34199XA030 INSTALLER & REMOVER 44
Using a press, press-fit until the groove of ST are aligned to the end surface of holder.

Fig 10: Identifying Groove And Holder
Courtesy of SUBARU OF AMERICA, INC.
Secure the gearbox in a vise using ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D

Fig 11: Securing Gearbox Using ST1 And ST2
Courtesy of SUBARU OF AMERICA, INC.
Tighten the holder.
Tightening torque:

85 N.m (8.7kgf-m, 62.7 ft-lb)

Fig 12: Tightening Holder
Courtesy of SUBARU OF AMERICA, INC.
Using the ST, crimp so that the diameter of punch hole is 2 - 2.5 mm (0.08 - 0.10 in) and is aligned to the position of 2 mm (0.08 in) from gearbox cylinder end surface.
ST 34099FA060 PUNCH HOLDER

Fig 13: Identifying Punch Hole Dimension
Courtesy of SUBARU OF AMERICA, INC.
Put a vinyl tape around the spline portion and apply genuine grease to the dust cover and install to valve assembly.
CAUTION: Be sure to install the dust cover to groove of shaft.

Fig 14: Installing Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Apply the genuine grease to the pinion gear and bearing of valve assembly.

Fig 15: Applying Genuine Grease To Pinion Gear And Bearing
Courtesy of SUBARU OF AMERICA, INC.
Install a new gasket on valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.

Fig 16: Installing Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts alternately to secure the valve assembly.
Tightening torque:

20 N.m (2.0 kgf-m, 14.8 ft-lb)

CAUTION: Be sure to alternately tighten the bolts.
Temporarily install the tie-rod to rack end, and then operate the rack from lock to lock for two or three times to make it fit in. Remove any grease blocking the air vent hole.
CAUTION: Operating the rack from lock to lock without installing tie-rods may damage the oil seal. Always install the left and right tie-rods.
Apply liquid gasket to more than 1/3 of entire perimeter of adjusting screw thread.
Liquid gasket:

THREE BOND 1141
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 17: Identifying Sleeve, Spring And Adjusting Screw
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to the specified torque.
Tightening torque:

5.9 N.m (0.6 kgf-m, 4.4 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it 20°.
Remove the tie-rod.
Adjust the turning resistance of gearbox so that it is within specification using adjusting screw. <Ref. to TURNING RESISTANCE OF GEARBOX , INSPECTION, Steering Gearbox.>
Apply liquid gasket to lock nut and install it into adjusting screw. While holding the adjusting screw with wrench, tighten the lock nut using ST.
Liquid gasket:

THREE BOND 1141

ST 926230000 SPANNER

Tightening torque (lock nut):

25 N.m (2.5 kgf-m, 18.1 ft-lb)

NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
Extend the rack approx. 40 mm (1.57 in) from steering body.
Install the tie-rod and new lock washer into rack.
Tightening torque:

128 N.m (13.1 kgf-m, 94.4 ft-lb)

Fig 18: Identifying Tie-Rod And Lock Washer
Courtesy of SUBARU OF AMERICA, INC.
Bend the lock washer and crimp it.
CAUTION: Be careful not to scratch the rack when crimping lock washer.

Fig 19: Identifying Lock Washer And Crimp
Courtesy of SUBARU OF AMERICA, INC.
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 20: Installing Boot To Housing
Courtesy of SUBARU OF AMERICA, INC.
Install a new boot band. Using band clamp pliers, crimp it so that the clearance of crimping portion becomes 2 mm (0.079 in) or less.

Fig 21: Identifying Boot Band
Courtesy of SUBARU OF AMERICA, INC.
Fix the boot end with small clip.

Fig 22: Identifying Clip Fix
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:

30 mm (1.2 in)

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

Holding the "B" tie-rod end, turn a few times as slowly as possible.

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

Fig 24: Holding Tie-Rod End
Courtesy of SUBARU OF AMERICA, INC.
Remove the gearbox from ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D
Install the four pipes on gearbox.
1. Connect the pipes A and B to the four pipe joints of gearbox.
  Tightening torque:
  
  Refer to the component parts. <Ref. to POWER ASSISTED SYSTEM , COMPONENT, General Description.>
2. Connect the pipes C and D to gearbox.
  Tightening torque:
  
  Pipe C: 37 N.m (3.8 kgf-m, 27.3 ft-lb)
  
  Pipe D: 29 N.m (3.0 kgf-m, 21.4 ft-lb)
  
  Fig 25: Identifying Pipes On Gearbox
  Courtesy of SUBARU OF AMERICA, INC.