Rack Housing Assembly

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

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

Fig 2: Inserting Special Tool (34199XA010) 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 34199XA020 FORMER PISTON 44

ST2 34199AG060 GUIDE G (26)

Fig 3: Installing Seal Ring To Piston Portion Of Rack Using Special Tool (34199XA020 And 34199AG060)
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 illustration.

Fig 4: Identifying Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Oil Seal, Rack And Piston
Courtesy of SUBARU OF AMERICA, INC.
Install the back-up washer from the gear side of rack.

Fig 6: Identifying Back-Up Washer And Rack
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.
Attach the ST on gearbox cylinder.
ST 34199XA000 INSTALLER 44
Set the ST to the end of rack.
ST 34199XA030 INSTALLER & REMOVER 44
Using a press, press-fit until the groove of ST1 is aligned to the end surface of ST2.
ST1 34199XA030 INSTALLER & REMOVER 44

ST2 34199XA000 INSTALLER 44

Fig 7: Identifying Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST.
Insert the outer side oil seal into the rack using the same procedure as steps 5) and 6).
ST 34199FE040 INSTALLER A, B, C
Make the ST and the pipe through the rack, and then press-fit the outer side oil seal using a press.
ST 34199XA000 INSTALLER 44

Fig 8: Pressing Outer Side Oil Seal Using Special Tool (34199XA000)
Courtesy of SUBARU OF AMERICA, INC.
Secure the gearbox in a vise using ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D

Fig 9: Identifying Clamp
Courtesy of SUBARU OF AMERICA, INC.
Tighten the holder.
Tightening torque: 85 N.m (8.7 kgf-m, 62.7 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 34199XA050 BASE

Fig 10: Identifying Punch Holder And 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: Applying Grease To Dust Cover
Courtesy of SUBARU OF AMERICA, INC.
Apply the genuine grease to the pinion gear and bearing of valve assembly.

Fig 12: Applying Grease To 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
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.
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 14: 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 using adjusting screw so that it is within specification. 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, 18.4 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: 128 N.m (13.1 kgf-m, 94.4 ft-lb)

Fig 15: 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 16: Identifying Lock Washer
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 17: Identifying Grease Applying Points
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 18: Identifying Boot Band
Courtesy of SUBARU OF AMERICA, INC.
Fix the boot end with small clip.

Fig 19: Identifying Clip
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 illustration.
Installed tie-rod length L: 28 mm (1.1 in)

Fig 20: Identifying Tie-Rod Length
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 21: 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 22: Identifying Gearbox Pipes C And D
  Courtesy of SUBARU OF AMERICA, INC.