Rack Housing Assembly

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

Fig 1: Installing Bushing To Gearbox
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Insert the ST to rack.
ST 34199AG030 GUIDE

Fig 2: Inserting ST 34199AG030 Guide To Rack
Courtesy of SUBARU OF AMERICA, INC.
Install the seal ring to piston portion of rack.
Using the ST, form the seal ring properly.
ST1 34199AG080 FORMER PISTON

ST2 34199AG050 GUIDE G (24)

Fig 3: Installing Seal Ring To Piston Portion Of Rack Using ST1 34199AG080 And ST2 34199AG050
Courtesy of SUBARU OF AMERICA, INC.
Attach the ST to the teeth of rack assembly, and insert the oil seal into the rack.
ST 926390001 COVER & REMOVER

Fig 4: Identifying ST 926390001 Cover & Remover On Teeth Of Rack Assembly
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST from the rack assembly.
Install the back-up washer from the gear side of rack.

Fig 5: Identifying Back-Up Washer And Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty.
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 a new holder to the gearbox cylinder.
Put a mark at the specified position measured from the end surface of ST, as shown in the figure.
Specified position:

Except for 2.5 GT-B and 3.0 R-LTD:

13.5 mm (0.53 in)

2.5 GT-B and 3.0 R-LTD:

18.9 mm (0.74 in)

ST 34199FE000 INSTALLER & REMOVER

Fig 6: Identifying Mark On ST 34199FE000 Installer & Remover
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 ST is aligned to the end surface of holder.

Fig 7: Setting ST 34199FE000 Installer & Remover On End Of Rack
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 5) and 6).
ST 926390001 COVER & REMOVER
Make the ST and the pipe through the rack, and then press-fit the outer side oil seal using a press.
ST 34199AG010 INSTALLER

Fig 8: Installing Outer Side Oil Seal Using ST 34199AG010 Installer
Courtesy of SUBARU OF AMERICA, INC.
Secure the gearbox in a vise using ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D

Fig 9: Securing Gearbox In Vise Using ST1 926200000 Stand And ST2 34199AG000 Boss D
Courtesy of SUBARU OF AMERICA, INC.
Tighten a new holder.
Tightening torque:

70 N.m (7.1 kgf-m, 51.6 ft-lb)
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.
ST1 34099FA060 PUNCH HOLDER

ST2 34199FE020 BASE

Fig 10: Crimping Using ST1 34099FA060 Punch Holder And ST2 34199FE020 Base
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 11: Installing Dust Cover To Groove Of Shaft
Courtesy of SUBARU OF AMERICA, INC.
Apply the genuine grease to the pinion gear and bearing of valve assembly.

Fig 12: Identifying Grease Applying Areas On Pinion Gear And Bearing Of Valve Assembly
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 13: Inserting Valve Assembly
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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.
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 1/3 or more 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 14: Identifying Grease Applying Areas On 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:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it 20°.
Tightening torque:

3.9 N.m (0.4 kgf-m, 2.9 ft-lb)
Remove the tie-rod.
Adjust the adjustment screw until the rotational resistance of gearbox is within specifications. Refer 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, 18.4 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:

90 N.m (9.1 kgf-m, 65.8 ft-lb)

Fig 15: Identifying Rack Extend Dimension
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 16: Crimping Lock Washer
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Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.
CAUTION: Right side boot has groove for identification, be sure to install the right and left of boot.

Fig 17: Identifying Right Side Boot And Groove For Identification
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Make sure that the boot is installed without unusual inflation or deflation.

Fig 18: Identifying Grease Applying Areas On Boot
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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 19: Identifying Clearance Of Crimping Portion
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Fix the boot end with small clip.

Fig 20: Fixing Boot End With Small Clip
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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:

31 mm (1.22 in)

Fig 21: Identifying Installed Tie-Rod Length L
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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 22: Inspecting Gearbox
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 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 23: Identifying Pipes C And D
  Courtesy of SUBARU OF AMERICA, INC.