Steering Gearbox: Installation

Insert the gearbox into crossmember, being careful not to damage gearbox boot.
Install the gearbox and bracket. Temporarily tighten the bolts.

Fig 1: Locating Gearbox Bracket Bolts
Courtesy of SUBARU OF AMERICA, INC.
Insert bolts through the clamp to temporarily tighten the gearbox to the crossmember bracket.

Fig 2: Locating Clamp Bolts
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts temporarily holding the gearbox clamp and bracket together to the specified torque.
Tightening torque:

60 N.m (6.1 kgf-m, 44.1 ft-lb)
Connect pipe D to the return hose, then connect pipe C to the pressure hose.
Tightening torque:

15 N.m (1.5 kgf-m, 10.8 ft-lb)

Fig 3: Identifying Pipe C And D
Courtesy of SUBARU OF AMERICA, INC.
Install the universal joint. Refer to INSTALLATION , Universal Joint.
Connect the tie-rod end and knuckle arm, and tighten with castle nut.
Castle nut tightening torque:

27 N.m (2.75 kgf-m, 19.9 ft-lb)

CAUTION: When connecting, do not hit the cap at the bottom of tie-rod end with hammer.
After tightening the castle nut to the specified tightening torque, tighten it further within 60° until the cotter pin hole is aligned with slot in the nut. Fit the cotter pin into the nut, and then bend the pin to lock.

Fig 4: Identifying Cotter Pin And Castle Nut
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Install the front stabilizer. Refer to INSTALLATION , Front Stabilizer.
Install the front crossmember support plate and jack-up plate.
Install the front exhaust pipe assembly. (Non-turbo model) Refer to INSTALLATION , Front Exhaust Pipe.
Install the undercover. Refer to INSTALLATION , Front Under Cover.
Install the front wheels.
Tighten the wheel nuts to the specified torque.
Tightening torque:

120 N.m (12.2 kgf-m, 88.5 ft-lb)
Lower the vehicle.
Remove the steering wheel. Refer to REMOVAL , Steering Wheel.
Align the center position of the roll connector. Refer to ADJUSTMENT , Roll Connector.
Install the steering wheel. Refer to INSTALLATION , Steering Wheel.
Connect the ground cable to battery.
Pour fluid into the oil tank, and bleed air. Refer to POWER STEERING FLUID .
Check for fluid leaks.
Check the fluid level in oil tank.
After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.
Tightening torque:

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

NOTE: When adjusting toe-in, hold the boot as shown to prevent it from being rotated or twisted. If it becomes twisted, straighten it.

Fig 5: Tightening Tie-Rod End Lock Nut
Courtesy of SUBARU OF AMERICA, INC.