Electric Power Steering Gearbox: Assembly

Install the tie-rod into rack.
Tightening torque:

90 N.m (9.2 kgf-m, 66.4 ft-lb)

NOTE: Check the mating face of rack and tie-rod for foreign matter such as dust etc.
Apply a coat of grease to the tie-rod groove, and then install the boot - steering gearbox to the housing.
NOTE: Make sure that the boot - steering gearbox is installed without unusual inflation or deflation.

Fig 1: Identifying Steering Gearbox Boot Grease Applying Area
Courtesy of SUBARU OF AMERICA, INC.
Using the boot clamp pliers, crimp the boot so that the clearance (b) of the band - boot (a) crimp portion becomes 2 mm (0.08 in) or less.
NOTE: Use a new band - boot.

Fig 2: Checking Crimp Boot Clearance
Courtesy of SUBARU OF AMERICA, INC.
Fix the end of the boot - steering gearbox with clip - boot tie-rod (a).
After installation, check that the end of the boot - steering gearbox is installed to the groove (b) of the tie-rod.

Fig 3: Fixing Boot Tie-Rod Clip
Courtesy of SUBARU OF AMERICA, INC.
If the tie-rod end has been removed, screw in lock nut and tie-rod end to the threaded portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length L:

29 mm (1.14 in)
Inspect the steering gearbox assembly as follows:
1. "A" Holding the tie-rod end, repeat lock to lock several times as quickly as possible.
2. "B" Holding the tie-rod end, turn it slowly at a radius several times as large as possible.
3. Finally, make sure that the boot - steering gearbox is installed in the specified position without inflating.
  
  Fig 4: Holding Tie-Rod End
  Courtesy of SUBARU OF AMERICA, INC.
Remove the steering gearbox assembly from ST.