Rack Housing Assembly

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

Fig 1: Installing Bushing To Gearbox Installation Portion
Courtesy of SUBARU OF AMERICA, INC.
Insert the ST into rack.
ST 34199AG030 GUIDE

Fig 2: Inserting ST Into Rack
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Install the seal ring to piston portion of rack.
1. 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
  Courtesy of SUBARU OF AMERICA, INC.
2. Using ST-B and ST-C, install the oil seal to ST-A.
  ST 927490000 INSTALLER A, B, C
  
  NOTE: Face the oil seal in the direction as shown in Fig 4 .
  
  Fig 4: Installing 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 From ST-A Near Piston
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Install the backup washer from gear side of rack.

Fig 6: Installing Backup Washer From Gear Side Of Rack
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Install the ST on rack, and equally apply a thin coat of grease to the rack and ST, then install the oil seal.
ST 926250000 GUIDE

CAUTION: Be careful not to scratch the oil seal lips with the inner ring section of piston.

Fig 7: Installing Oil Seal
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 thread part of holder and end of gearbox cylinder for burrs and scratches. Correct if necessary.
Insert the ST into gearbox cylinder, and then press-fit the oil seal.
ST 34199AG010 INSTALLER

Fig 8: Inserting ST Into Gearbox Cylinder
Courtesy of SUBARU OF AMERICA, INC.
Temporarily install the holder to gearbox cylinder.
Set the ST to the end of rack.
ST 34099FA030 INSTALLER & REMOVER
Using a press, press-fit until the groove of ST reaches the end of holder.

Fig 9: Installing Holder To Gearbox Cylinder
Courtesy of SUBARU OF AMERICA, INC.
Secure the gearbox in a vice using ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D

Fig 10: Securing Gearbox In Vice
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Tighten the holder.
Tightening torque:

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

Fig 11: Tightening Holder
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Using ST, caulk the gearbox cylinder at 2 mm (0.08 in) from end to make punch hole 2 to 2.5 mm (0.08 to 0.10 in) in diameter.
ST 34099FA060 PUNCH HOLDER

Fig 12: Identifying Dimensions Of Gearbox Cylinder
Courtesy of SUBARU OF AMERICA, INC.
Apply vinyl tape to spline portion, and apply genuine grease to dust cover, and then install the dust cover to valve assembly.
CAUTION: Be sure to install the dust cover to groove on shaft properly.

Fig 13: Installing Dust Cover To Groove On Shaft
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Apply genuine grease to the pinion gear and bearing of valve assembly.

Fig 14: Applying Grease To Pinion Gear And Bearing Of Valve Assembly
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Install a new gasket on valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.

Fig 15: Installing Gasket On Valve Assembly
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Tighten the bolts alternately to secure 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 rack, and then operate it from lock to lock two or three times to make it fit in. Remove the grease blocking air vent hole.
CAUTION: If operating the rack from lock to lock without installing tie-rod, it may damage the oil seal. Always install the tie-rods LH and RH.
Apply liquid gasket to at least 1/3 of the 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 sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw and install on steering body.

Fig 16: Installing Steering Body
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to specified torque.
Tightening torque:

3.9 N.m (0.4 kgf-m, 2.9 ft-lb)
After tightening the adjusting screw with the specified tightening torque, loosen it by 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 a wrench, tighten 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) beyond side of steering body.
Install the tie-rod and a new lock washer into rack.
Tightening torque:

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

Fig 17: Installing Tie-Rod And A New Lock Washer Into Rack
Courtesy of SUBARU OF AMERICA, INC.
Bend the lock washer.
CAUTION: Be careful not to scratch the rack when bending lock washer.

Fig 18: Bending Lock Washer
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Apply a coat of grease to the tie-rod groove, and then install the boot to housing.
CAUTION: Right side boot has groove for identification. Be sure to install the boots after identifying left and right boots.

Fig 19: Installing Boot To Housing
Courtesy of SUBARU OF AMERICA, INC.

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

Fig 20: Identifying Unusual Inflation Or Deflation
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Install a new boot band. Using band clamp pliers, caulk the boot band until caulking part clearance is 2 mm (0.079 in) or less.

Fig 21: Installing Boot Band
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Fix the boot end with clip (small).

Fig 22: Fixing Boot End With Clip
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After installing, check the boot end is positioned into groove on tie-rod.
If the tie-rod end has been removed, screw in the lock nut and tie-rod end to screwed portion of tie-rod, and then tighten the lock nut temporarily in a position as shown in Fig 23 .
Installed tie-rod length L:

31 mm (1.22 in)

Fig 23: Identifying Installed Tie-Rod Length L
Courtesy of SUBARU OF AMERICA, INC.
Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock two or three times as quickly as possible.

"B" Holding the tie-rod end, turn it slowly at a radius one or two times as large as possible.

After all, make sure that the boot is installed in specified position without deflation.

Fig 24: 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.

Connect the pipe A and B to four pipe joints of gearbox.
Tightening torque:

Refer to POWER ASSISTED SYSTEM , COMPONENT, General Description.
Connect the pipe 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: Connecting Pipe C And D To Gearbox
Courtesy of SUBARU OF AMERICA, INC.