Control Valve Assembly

Specified steering grease: 

VALIANT GREASE M2 (Part No. 003608001) 

1. Clean all parts and tools before reassembling.
2. Apply a coat of specified power steering fluid to the inner wall of valve housing.
   Fig 1: Identifying Oil Seal Grease Applying Area

   Courtesy of SUBARU OF AMERICA, INC.
3. Apply grease to the oil seal.
4. Verify the direction of oil seal.
5. Using the ST and a press, install the oil seal and the bushing in valve housing.

   ST 34199AG090 INSTALLER & REMOVER

   Fig 2: Installing Oil Seal And Bushing In Valve Housing Using ST And Press

   Courtesy of SUBARU OF AMERICA, INC.
6. Apply vinyl tape to the groove of pinion.
7. Install the back-up ring and oil seal to pinion, and then remove the vinyl tape.
   Fig 3: Identifying Oil Seal, Vinyl Tape And Back-Up Ring

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8. Attach the ST to pinion, and install the seal ring.

   ST 34199AG020 GUIDE

   Fig 4: Installing Seal Ring Using ST

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9. Remove the ST GUIDE, and form the seal ring properly using ST FORMER.

   ST 34199AG070 FORMER

   Fig 5: Removing ST Guide Form Seal Ring

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10. Put vinyl tape around pinion shaft spline to protect oil seal from damage.
11. Install the valve to pinion, and install the snap ring.
    Fig 6: Identifying Snap Ring And Valve

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12. Attach the pinion & valve assembly into the valve housing.
    Fig 7: Identifying Valve Housing And Pinion & Valve Assy

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13. Using the ST and a press, push the outer race of bearing and press-fit the pinion and valve assembly into housing.

    ST 34199XA020 FORMER PISTON 44

    Fig 8: Pressing To Fit Pinion And Valve Assembly Into Housing Using ST And Press

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14. Apply the specified grease to dust cover.
15. Install the dust cover on valve assembly.
    CAUTION: Be sure to install the dust cover to groove of shaft.
    Fig 9: Installing Dust Cover On Valve Assembly

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16. Apply the genuine grease to the pinion gear and bearing of valve assembly.
    Fig 10: Identifying Valve Assembly Pinion Gear And Bearing Grease Applying Area

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17. Install new O-ring to valve assembly.
    Fig 11: Identifying Valve Assembly O-Ring

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18. Insert the valve assembly into place while facing the rack teeth toward pinion.
    Fig 12: Inserting Valve Assembly Into Place

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19. 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.
20. Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.

    Liquid gasket: 

    THREE BOND 1102 or 1215 

21. 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 13: Identifying Sleeve, Spring And Adjusting Screw Grease Applying Area

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22. Tighten the adjusting screw to the specified torque.

    Tightening torque: 

    5.9 N.m (0.6 kgf-m, 4.4 ft-lb) 

23. Tighten the adjusting screw to the specified torque, then loosen it 20°.
24. Adjust the turning resistance of gearbox so that it is within specification using adjusting screw. < Ref. to TURNING RESISTANCE OF GEARBOX , INSPECTION, Steering Gearbox. >
25. Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.

    Liquid gasket: 

    THREE BOND 1102 or 1215 

    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.
26. Remove the gearbox from ST.

    ST1 926200000 STAND

    ST2 34199AG000 BOSS D

27. Install the four pipes on gearbox.
    1. Connect the pipes A and B to 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 14: Identifying Gearbox Pipes

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