Control Valve Assembly

WARNING: This page is about a different car, the 2004 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Specified steering grease:

VALIANT GREASE M2 (Part No. 003608001)

Clean all parts and tools before reassembling.
Apply a coat of specified power steering fluid to the inner wall of valve housing.

Fig 1: Applying Coat Of Specified Power Steering Fluid To Inner Wall Of Valve Housing
Courtesy of SUBARU OF AMERICA, INC.
Attach the ST2 to ST1.
ST1 34099FA120 INSTALLER & REMOVER SEAL

ST2 34099FA130 INSTALLER SEAL
To avoid scratching the oil seal, apply a coat of grease to the contact surface of installer and oil seal.
Verify the oil seal direction.
Attach the oil seal to installer and position in valve housing before pressing into place.
Press the oil seal into place using a press.

Fig 2: Installing Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Attach the bearing to ST, and then position in value housing. Using the ST and press, install the special bearing in valve housing.

Fig 3: Installing Special Bearing In Valve Housing
Courtesy of SUBARU OF AMERICA, INC.
Put vinyl tape around the pinion shaft splines to protect oil seal from damage.
Fit the pinion and valve assembly into valve housing.
Secure the valve assembly to ST1 and ST2.
ST1 926370000 INSTALLER A

ST2 34099FA100 STAND BASE
Apply specified power steering fluid to oil seal and ST3.
Install the ST3 to pinion, and then insert the oil seal. Press the oil seal using a press until ST4 contacts face end of valve housing.

Fig 4: Installing Oil Seal
Courtesy of SUBARU OF AMERICA, INC.
Remove the ST3, and then fit the back-up washer.
Force-fit the ball bearing using ST3.

Fig 5: Fitting Ball Bearing Using ST3
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Be careful not to tilt the ball bearing during installation.
Install the snap ring using snap ring pliers.
NOTE: Rotate the snap ring to check for proper installation.
Apply the specified grease to dust cover.
Install the dust cover on valve assembly.

Fig 6: Installing Dust Cover On Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Apply genuine grease to the pinion gear and bearing of valve assembly.

Fig 7: Applying Genuine 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 rack teeth toward pinion.

Fig 8: Inserting Valve Assembly
Courtesy of SUBARU OF AMERICA, INC.
Tighten the bolts alternately to secure valve assembly.
Tightening torque:

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

CAUTION: Be sure to alternately tighten the bolts.
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 9: Applying Coat Of Grease To Sliding Surface Of Sleeve And Seating Surface Of Spring
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to specified torque.
Tightening torque:

7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
After tightening to the specified tightening torque, loosen it by 25°.
Verify that play is within specified value. < Ref. to SERVICE LIMIT <-- , INSPECTION, Steering Gearbox -->.>
Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of adjusting screw thread.
Liquid gasket:

THREE BOND 1141

Fig 10: Identifying Liquid Gasket Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Tighten the adjusting screw to specified torque.
Tightening torque:

7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
After tightening to the specified tightening torque, loosen it by 25°.
Install the lock nut. While holding the adjusting screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER

Tightening torque (Lock nut):

39 N.m (4.0 kgf-m, 28.9 ft-lb)

NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
Remove the gearbox from ST.
Install the four pipes on gearbox.
1. Connect the pipe A and B to the gearbox.
  Tightening torque:
  
  13 N.m (1.3 kgf-m, 9.4 ft-lb)
2. Connect the pipe E and F to gearbox.
  Tightening torque:
  
  Pipe E: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
  
  Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)