Control Valve Assembly

Specified steering grease: 

VALIANT GREASE M2 

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 Grease Applying Area On Control Valve Assembly

   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.

   Preparation tool: 

   ST: INSTALLER & REMOVER (34199AG090) 

   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 wave washer and oil seal to pinion, and then remove the vinyl tape.
   Fig 3: Identifying Oil Seal, Vinyl Tape, Wave Washer

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

   Preparation tool: 

   ST: GUIDE (34199AG020) 

   Fig 4: Identifying Seal Ring And O-Ring

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

   Preparation tool: 

   ST: FORMER (34199AG070) 

   Fig 5: Identifying ST Guide And 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 Pinion And Valve Assembly And Valve Housing

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13. Using a press, push the outer race of bearing and press-fit the pinion & valve assembly into housing.
    Fig 8: Pushing Outer Race Of Bearing Using Press

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14. Apply the specified grease to the dust cover and fill it to the clearance between pinion shaft and housing.
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 edge and body of pinion gear and bearing of valve assembly.
    Fig 10: Identifying Grease Applying Area On Pinion Gear Body

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17. Apply grease to a new O-ring and attach it to the valve assembly.
    Fig 11: Identifying Grease Applying Area On O-Ring

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18. Insert the valve assembly into the given place while facing the rack teeth toward pinion.
    CAUTION: Check that the needle bearing is not damaged. Replace with a new steering gearbox if damage is found.
    Fig 12: Checking Needle Bearing

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19. Tighten the bolts alternately to secure the valve assembly.
    CAUTION: Be sure to alternately tighten the bolts.

    Tightening torque: 

    20 N.m (2.0 kgf-m, 14.8 ft-lb) 

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

    Liquid gasket: 

    THREE BOND 1102 

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 Grease Applying Area On Sleeve, Spring, Adjusting Screw

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22. Tighten the adjusting screw to the specified torque, then loosen it.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb) 

23. Tighten the adjusting screw to the specified torque, then loosen it 5°.

    Tightening torque: 

    5.9 N.m (0.6 kgf-m, 4.4 ft-lb) 

24. Adjust the turning resistance of gearbox so that it is within specification using adjusting screw. <Ref. to LIMIT , 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.

    Preparation tool: 

    ST: SPANNER (926230000) 

    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.

    Preparation tool: 

    ST1: STAND (926200000) 

    ST2: BOSS D (34199AG000) 

27. Install the four pipes on gearbox.
    1. Connect the pipes A and B to gearbox.

       Tightening torque: 

       Cylinder side: 27 N.m (2.8 kgf-m, 19.9 ft-lb) 

       Gear housing side: 17 N.m (1.7 kgf-m, 12.5 ft-lb) 

    2. Connect the feed pipe and return pipe to the gearbox.

       Tightening torque: 

       Feed pipe: 37 N.m (3.8 kgf-m, 27.3 ft-lb) 

       Return pipe: 29 N.m (3.0 kgf-m, 21.4 ft-lb) 

    Fig 14: Identifying Feed And Return Pipe

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28. Cut out the shaded area of the guide chip using a pair of nippers, etc., and attach by aligning with the groove of the spline. (Install in any direction. See the cross section.) If the guide chip is not installed, the position of the U/J mounting bolt may move that may cause failure of installation. (Model with guide chip only)

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    (1)	Cut-out area
    (2)	Groove of spline part
    (3)	Guide chip
    (4)	Cross section