Subaru Car 1998-05

Removal & Installation

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Click image to see an enlarged view

Fig. Exploded view of the steering rack assembly-Legacy models

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Front axle nut, loosen only at this time
     
    Front tire and wheel assemblies
     
    Electrical connector from the Oxygen Sensor (O2S)
     
    Front exhaust pipe assembly
     
    Tie rod end cotter pin and loosen the castle nut
     
    Tie rod ends from the steering knuckle arm using a ball joint puller
     
    Jack up plate and the front stabilizer bar
     

  4.  
  5. From the power steering rack, remove the center pressure pipe, connect a vinyl hose to the pipe and joint, then turn the steering wheel to discharge the fluid into a container.
  6.  


NOTE
When discharging the power steering fluid (line A and B), turn the steering wheel fully, left and right. Be sure to disconnect the other pipe and drain the fluid in the same manner.

  1. From the control valve of the gearbox assembly, remove the power steeringCDDC
  2.  
  3. If not disconnected when draining the fluid from the control valve of the gearbox assembly, remove the power steeringABAB
  4.  
  5. Remove or disconnect the following:

    Universal joint assembly. Matchmark the assembly before removal.
     
    Power steering gearbox-to-crossmember assembly bolts
     
    Gearbox assembly from the vehicle
     

  6.  

To install:

  1. Install or connect the following:

    Power steering rack and tighten the rack to crossmember bolts to 35-52 ft. lbs. (47-70 Nm)
     
    Universal joint assembly making sure to align the matchmarks
     
    Power steering pressure pipes and tighten to 7-12 ft. lbs. (10-16 Nm)
     
    Universal joint assembly-to-power steering gearbox bolts and tighten to 16-19 ft. lbs. (22-24 Nm) and the universal joint assembly-to-steering shaft bolts 16-19 ft. lbs. (22-24 Nm)
     
    Tie rod end to steering knuckle nut and tighten to 18-22 ft. lbs. (25-29 Nm). After tightening this nut, turn it no more than 60 degrees further to align the cotter pin hole.
     
    New cotter pin
     
    Front stabilizer into the vehicle
     
    Exhaust Y-pipe and O2S connector
     
    Tires and tighten the wheel lug nuts to specification
     

  2.  
  3. Partially lower the vehicle, then refill and bleed the power steering system.
  4.  
  5. Check for fluid leaks and the fluid level, then install the jack up plate.
  6.  
  7. Check and adjust the toe-in and the steering angle.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Under cover
     
    Bolt, clip on the sub-frame
     
    Sub-frame bolts. Leave bolt (1) connected by a few threads and remove the bolts in the sequence illustrated. Once the other bolts are removed, remove bolt (1) and the sub-frame. Refer to the illustration for bolt location.
     


    Click image to see an enlarged view

    Fig. Remove the sub-frame bolts as illustrated-Impreza models

    Front Y-pipe
     
    Tie rod end cotter pin and nut
     
    Tie rod ends from the steering knuckle using a puller
     
    Jack-up plate and front sway bar
     
    Fluid lines from the rack and pinion
     

  4.  
  5. Matchmark the universal joint to the serration in the steering rack for installation reference.

    Lower and upper universal joint bolts and lift the joint upward, disconnecting it from the rack and pinion shaft
     
    Clamp bolts securing the rack and pinion to the crossmember
     
    Rack and pinion
     

  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the steering rack assembly-Impreza models


To install:

  1. Install the rack and pinion. Tighten the clamp bolts to 43 ft. lbs. (59 Nm).

    Fluid pipes and tighten to 9 ft. lbs. (13 Nm)
     

  2.  
  3. Align the steering rack to the universal joint. Push the long yoke of the joint all the way into the serrated position of the steering shaft, setting the bolt hole in the cut-out. Pull the short yoke all the way out of the serrated portion of the rack and pinion, setting the bolt hole in the cut-out. Insert the bolt through the short yoke. Pull the yoke and ensure the bolt is properly engaged in the cut-out. Fasten the short yoke side with the spring washer and bolt, then fasten the yoke side. Tighten the bolts to 17 ft. lbs. (24 Nm).
  4.  
  5. Install or connect the following:

    Tie rod ends to the steering knuckle
     
    Sway bar and jack-up plate
     
    Y-pipe with new gaskets and nuts
     
    Sub-frame. Tighten the T1 bolts to 25 ft. lbs. (34 Nm), the T2 bolts to 41 ft. lbs. (55 Nm) and the T3 bolts to 52 ft. lbs. (71 Nm).
     
    Wheels
     

  6.  
  7. Fill and bleed the steering system.
  8.  


    Click image to see an enlarged view

    Fig. Tighten the sub-frame bolts to the sequences outlined in the procedure-Impreza models




Click image to see an enlarged view

Fig. Exploded view of the steering rack assembly-Legacy models

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Front axle nut, loosen only at this time
     
    Front tire and wheel assemblies
     
    Electrical connector from the Oxygen sensor (O 2 S)
     
    Front exhaust pipe assembly
     
    Tie rod end cotter pin and loosen the castle nut
     
    Tie rod ends from the steering knuckle arm using a ball joint puller
     
    Jack up plate and the front stabilizer bar
     

  4.  
  5. From the power steering rack, remove the center pressure pipe, connect a vinyl hose to the pipe and joint, then turn the steering wheel to discharge the fluid into a container.
    NOTE
    When discharging the power steering fluid (line A and B), turn the steering wheel fully, left and right. Be sure to disconnect the other pipe and drain the fluid in the same manner.

  6.  
  7. From the control valve of the gearbox assembly, remove the power steering C and D pressure pipes. Remove pipe D first and pipe C second.
  8.  
  9. If not disconnected when draining the fluid from the control valve of the gearbox assembly, remove the power steering A and B pressure pipes. Remove pipe A first and pipe B second.
  10.  
  11. Remove or disconnect the following:

    Universal joint assembly. Matchmark the assembly before removal.
     
    Power steering gearbox-to-crossmember assembly bolts
     
    Gearbox assembly from the vehicle
     

  12.  

To install:

  1. Install or connect the following:

    Power steering rack and tighten the rack to crossmember bolts to 35-52 ft. lbs. (47-70 Nm)
     
    Universal joint assembly making sure to align the matchmarks
     
    Power steering pressure pipes and tighten to 7-12 ft. lbs. (10-16 Nm)
     
    Universal joint assembly-to-power steering gearbox bolts and tighten to 16-19 ft. lbs. (22-24 Nm) and the universal joint assembly-to-steering shaft bolts 16-19 ft. lbs. (22-24 Nm)
     
    Tie rod end to steering knuckle nut and tighten to 18-22 ft. lbs. (25-29 Nm). After tightening this nut, turn it no more than 60 degrees further to align the cotter pin hole.
     
    New cotter pin
     
    Front stabilizer into the vehicle
     
    Exhaust Y-pipe and O 2 S sensor connector
     
    Tires and tighten the wheel lug nuts to specification
     

  2.  
  3. Partially lower the vehicle, then refill and bleed the power steering system.
  4.  
  5. Check for fluid leaks and the fluid level, then install the jack up plate.
  6.  
  7. Check and adjust the toe-in and the steering angle.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Front Y-pipe
     
    Tie rod end cotter pin and nut
     
    Tie rod ends from the steering knuckle using a puller
     
    Jack-up plate and front sway bar
     
    Fluid lines from the rack and pinion
     

  4.  
  5. Matchmark the universal joint to the serration in the steering rack for installation reference.

    Lower and upper universal joint bolts and lift the joint upward, disconnecting it from the rack and pinion shaft
     
    Clamp bolts securing the rack and pinion to the crossmember
     
    Rack and pinion

    Click image to see an enlarged view

    Fig. Exploded view of the steering rack assembly-Impreza models

     

  6.  

To install:

  1. Install the rack and pinion. Tighten the clamp bolts to 43 ft. lbs. (59 Nm).
  2.  
  3. Align the steering rack to the universal joint. Push the long yoke of the joint all the way into the serrated position of the steering shaft, setting the bolt hole in the cut-out. Pull the short yoke all the way out of the serrated portion of the rack and pinion, setting the bolt hole in the cut-out. Insert the bolt through the short yoke. Pull the yoke and ensure the bolt is properly engaged in the cut-out. Fasten the short yoke side with the spring washer and bolt, then fasten the yoke side. Tighten the bolts to 17 ft. lbs. (24 Nm).
  4.  
  5. Install or connect the following:

    Tie rod ends to the steering knuckle
     
    Sway bar and jack-up plate
     
    Y-pipe with new gaskets and nuts
     
    Wheels
     

  6.  
  7. Fill and bleed the steering system.
  8.  



Click image to see an enlarged view

Fig. Loosening the steering column-to-rack pinch bolt-Legacy (1997)



Click image to see an enlarged view

Fig. Removing the steering rack retainer bolts (1997)



Click image to see an enlarged view

Fig. Steering rack pressure pipes (1997)



Click image to see an enlarged view

Fig. Disconnect pipe D first, followed by pipe C (1997)

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the front tire and wheel assemblies.
  6.  
  7. Disconnect the electrical connector from the oxygen sensor. Remove the front exhaust pipe assembly.
  8.  
  9. Remove the tie rod end cotter pin and loosen the castle nut. Using a ball joint puller, separate the tie rod ends from the steering knuckle arm.
  10.  
  11. Remove the jack up plate and the front stabilizer bar.
  12.  
  13. From the power steering rack, remove the center pressure pipe, connect a vinyl hose to the pipe and joint, then turn the steering wheel to discharge the fluid into a container.
    NOTE
    When discharging the power steering fluid (line A and B), turn the steering wheel fully, left and right. Be sure to disconnect the other pipe and drain the fluid in the same manner.

  14.  
  15. From the control valve of the gearbox assembly, remove the power steering C and D pressure pipes. Remove pipe D first and pipe C second.
  16.  
  17. If not disconnected when draining the fluid from the control valve of the gearbox assembly, remove the power steering A and B pressure pipes. Remove pipe A first and pipe B second.
  18.  
  19. Remove the power steering gearbox to crossmember assembly bolts. Remove the gearbox assembly from the vehicle.
  20.  

To install:

  1. Install the power steering rack and tighten the rack to crossmember bolts to 35-52 ft. lbs. (47-70 Nm). When installing the universal joint assembly, be sure to align the matchmarks.
  2.  
  3. Tighten the power steering pressure pipes 7-12 ft. lbs. (10-16 Nm), the universal joint assembly to power steering gearbox bolts 16-19 ft. lbs. (22-24 Nm) and the universal joint assembly to steering shaft bolts 16-19 ft. lbs. (22-24 Nm).
  4.  
  5. Tighten the tie rod end to steering knuckle nut 18-22 ft. lbs. (25-29 Nm). After torquing this nut, turn it up to 60 degrees further to align the cotter pin hole. Install a new cotter pin.
  6.  
  7. Install the tires and tighten the wheel lug nuts to specification.
  8.  
  9. Refill and bleed the power steering system.
  10.  
  11. Check and adjust the toe-in and the steering angle.
  12.  

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the front wheels.
  6.  
  7. Remove the front Y-pipe.
  8.  
  9. Remove the tie rod end cotter pin and nut. Using a puller, disconnect the tie rod ends from the steering knuckle.
  10.  
  11. Remove the jack-up plate and front sway bar.
  12.  
  13. Disconnect the fluid lines from the rack and pinion.
  14.  
  15. Matchmark the universal joint to the serration in the steering rack for installation reference.
  16.  
  17. Remove the universal joint bolts and lift the joint upward disconnecting it from the rack and pinion shaft.
  18.  
  19. Remove the clamps bolts securing the rack and pinion to the crossmember. Remove the rack and pinion.
  20.  

To install:

  1. Install the rack and pinion and tighten the clamp bolts to 43 ft. lbs. (59 Nm).
  2.  
  3. Align the steering rack to the universal joint. Push the long yoke of the joint all the way into the serrated position of the steering shaft, setting the bolt hole in the cut-out. Pull the short yoke all the way out of the serrated portion of the rack and pinion, setting the bolt hole in the cut-out. Insert the bolt through the short yoke. Pull the yoke and ensure the bolt is properly engaged in the cut-out. Fasten the short yoke side with the spring washer and bolt, then fasten the yoke side. Tighten the bolts to 17 ft. lbs. (24 Nm). Install and secure all remaining components.
  4.  
  5. Fill and bleed the steering system.
  6.  



Click image to see an enlarged view

Fig. Remove the steering rack retainer bolts-SVX

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the O 2 sensor connector and the steering harness connector.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the front under cover.
  8.  
  9. Disconnect the O 2 sensor harness from the clip.
  10.  
  11. Remove the collector cover and rear catalytic converter cover.
  12.  
  13. Disconnect the front exhaust pipe.
  14.  
  15. Remove the cotter pin and castle nut from the outer tie rod ends and separate the tie rods from the steering knuckles using a suitable puller.
  16.  
  17. Remove the spring pin securing the halfshaft to the transaxle.
  18.  
  19. Disconnect the halfshaft from the transaxle.
  20.  
  21. Disconnect the power steering lines one at a time. After disconnecting each allow the line to hang into a drain pan while you rotate the wheel lock to lock. This will purge the power steering fluid from the rack and pinion unit.
  22.  
  23. Disconnect and remove the performance rod.
  24.  
  25. Remove the lower ball joint pinch bolt on the right side. Separate the ball joint from the steering knuckle.
  26.  
  27. Matchmark the universal joint to the rack and pinion unit and the steering shaft.
  28.  
  29. Remove the upper and lower pinch bolts on the universal joint and push the joint up to remove it from the rack and pinion unit. Once it clears the rack pull it down and off the steering shaft.
  30.  
  31. Remove the bolts securing the rack and pinion unit to the vehicle underbody.
  32.  
  33. Remove the rack by performing the following:
    1. Turn the rack so the control valve faces the rear.
    2.  
    3. Move the rack to the right so the left tie rod can be removed from the rack assembly.
    4.  
    5. Remove the rack from the vehicle.
    6.  

  34.  
  35. Installation is the reverse of removal. Tighten all components to specifications.

    Rack mounting bolts-44 ft. lbs. (59 Nm)
     
    Tie rod ends-to-steering knuckle castle nuts-29 ft. lbs. (39 Nm).
     

  36.  
  37. Check the front end alignment and adjust as necessary.
  38.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Under cover
     
    Bolt, clip on the sub-frame
     
    Sub-frame bolts. Leave bolt (1) connected by a few threads and remove the bolts in the sequence illustrated. Once the other bolts are removed, remove bolt (1) and the sub-frame. Refer to the illustration for bolt location.
     
    Front Y-pipe
     
    Tie rod end cotter pin and nut
     
    Tie rod ends from the steering knuckle using a puller
     
    Jack-up plate and front sway bar
     
    Fluid lines from the rack and pinion
     

  2.  
  3. Matchmark the universal joint to the serration in the steering rack for installation reference.

    Lower and upper universal joint bolts and lift the joint upward, disconnecting it from the rack and pinion shaft
     
    Clamp bolts securing the rack and pinion to the crossmember
     
    Rack and pinion
     

  4.  

To install:

  1. Install the rack and pinion. Tighten the clamp bolts to 43 ft. lbs. (59 Nm).

    Fluid pipes and tighten to 9 ft. lbs. (13 Nm)
     

  2.  
  3. Align the steering rack to the universal joint. Push the long yoke of the joint all the way into the serrated position of the steering shaft, setting the bolt hole in the cut-out. Pull the short yoke all the way out of the serrated portion of the rack and pinion, setting the bolt hole in the cut-out. Insert the bolt through the short yoke. Pull the yoke and ensure the bolt is properly engaged in the cut-out. Fasten the short yoke side with the spring washer and bolt, then fasten the yoke side. Tighten the bolts to 17 ft. lbs. (24 Nm).
  4.  
  5. Install or connect the following:

    Tie rod ends to the steering knuckle
     
    Sway bar and jack-up plate
     
    Y-pipe with new gaskets and nuts
     
    Sub-frame. Tighten the T1 bolts to 25 ft. lbs. (34 Nm), the T2 bolts to 41 ft. lbs. (55 Nm) and the T3 bolts to 52 ft. lbs. (71 Nm).
     
    Wheels
     

  6.  
  7. Fill and bleed the steering system.

    Click image to see an enlarged view

    Fig. Sub frame bolt tightening sequence-2002-2004 Impreza and WRX

  8.  



Click image to see an enlarged view

Fig. Typical steering rack and related components-Legacy

  1. Remove or disconnect the following:

    Negative battery cable
     
    Air intake duct
     
    Front axle nut, loosen only at this time
     
    Front tire and wheel assemblies
     
    Electrical connector from the Oxygen Sensor (O 2 S)
     
    Front exhaust pipe assembly
     
    Tie rod end cotter pin and loosen the castle nut
     
    Tie rod ends from the steering knuckle arm using a ball joint puller
     
    Jack up plate and the front stabilizer bar
     

  2.  
  3. From the power steering rack, remove the center pressure pipe, connect a vinyl hose to the pipe and joint, then turn the steering wheel to discharge the fluid into a container.
    NOTE
    When discharging the power steering fluid (line A and B), turn the steering wheel fully, left and right. Be sure to disconnect the other pipe and drain the fluid in the same manner.

  4.  
  5. From the control valve of the gearbox assembly, remove the power steering C and D pressure pipes. Remove pipe D first and pipe C second.
  6.  
  7. If not disconnected when draining the fluid from the control valve of the gearbox assembly, remove the power steering A and B pressure pipes. Remove pipe A first and pipe B second.
  8.  
  9. Remove or disconnect the following:

    Universal joint assembly. Matchmark the assembly before removal.
     
    Power steering gearbox-to-crossmember assembly bolts
     
    Gearbox assembly from the vehicle
     

  10.  

To install:

  1. Install or connect the following:

    Power steering rack and tighten the rack to crossmember bolts to 35-52 ft. lbs. (47-70 Nm)
     
    Universal joint assembly making sure to align the matchmarks
     
    Power steering pressure pipes and tighten to 7-12 ft. lbs. (10-16 Nm)
     
    Universal joint assembly-to-power steering gearbox bolts and tighten to 16-19 ft. lbs. (22-24 Nm) and the universal joint assembly-to-steering shaft bolts 16-19 ft. lbs. (22-24 Nm)
     
    Tie rod end to steering knuckle nut and tighten to 18-22 ft. lbs. (25-29 Nm). After tightening this nut, turn it no more than 60 degrees further to align the cotter pin hole.
     
    New cotter pin
     
    Front stabilizer into the vehicle
     
    Exhaust Y-pipe and O 2 S connector
     
    Tires and tighten the wheel lug nuts to specification
     

  2.  
  3. Partially lower the vehicle, then refill and bleed the power steering system.
  4.  
  5. Check for fluid leaks and the fluid level, then install the jack up plate.
  6.  
  7. Check and adjust the toe-in and the steering angle.
  8.  



Click image to see an enlarged view

Fig. Typical steering rack and related components-Impreza

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the front wheel nut.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the tires and wheels.
  8.  
  9. Remove the under cover.
  10.  
  11. Remove the sub frame. Leave bolt (1) connected by a few threads and remove the bolts in the sequence illustrated. Once the other bolts are removed, remove bolt (1) and the sub frame.

    Click image to see an enlarged view

    Fig. Sub frame bolt removal sequence-Impreza and WRX

  12.  
  13. Remove the front exhaust pipe.
  14.  
  15. Remove the cotter pin and castle nut. Using a puller, remove the tie rod end from the knuckle arm.
  16.  
  17. Remove the jack up plate. Remove the front stabilizer.
  18.  
  19. Disconnect the power steering fluid pipe at the center of the gearbox and attach a vinyl hose. Discharge the fluid into a suitable container by turning the steering wheel fully clockwise and counterclockwise. Disconnect the other fluid line, and repeat the discharge procedure.
  20.  
  21. Remove the steering wheel. Make a matchmark on the universal joint. Remove the universal joint bolts and remove the joint from the vehicle.
  22.  
  23. Disconnect the fluid lines from the steering gear, pressure hose first.
  24.  
  25. Remove the steering gear retaining bolts and clamps securing the steering gear to the crossmember. Remove the steering gear from the vehicle.
  26.  

To install:

  1. Insert the steering gear into the crossmember. Be careful not to damage the gearbox boot.
  2.  
  3. Tighten the steering gear to the crossmember bracket to 44.3 ft. lbs.
  4.  
  5. Connect the fluid lines.
  6.  
  7. Align the cutout at the serrated section of the column shaft and yoke. Insert the universal joint into the column shaft.
  8.  
  9. Align the mating marks and insert the universal joint to serrated section of the steering gear assembly. Tighten the bolt to 17.4 ft. lbs.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. When installing the sub frame be sure to torque the bolts to specification and in the proper sequence.

    Click image to see an enlarged view

    Fig. Sub frame bolt tightening sequence-2005 Impreza and WRX

  14.  
  15. Fill the power steering system with the proper grade and type fluid.
  16.  
  17. Start the engine and check for leaks. Correct as required.

    Click image to see an enlarged view

    Fig. Steering column joint alignment-2005

  18.  

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the front wheel nut.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the tires and wheels.
  8.  
  9. Remove the under cover.
  10.  
  11. Remove the front exhaust pipe.
  12.  
  13. Remove the cotter pin and castle nut. Using a puller, remove the tie rod end from the knuckle arm.
  14.  
  15. Remove the front crossmember support plate. Remove the jack up plate. Remove the front stabilizer.
  16.  
  17. Disconnect the power steering fluid pipe at the center of the gearbox and attach a vinyl hose. Discharge the fluid into a suitable container by turning the steering wheel fully clockwise and counterclockwise. Disconnect the other fluid line, and repeat the discharge procedure.
  18.  
  19. Remove the steering wheel. Make a matchmark on the universal joint. Remove the universal joint bolts and remove the joint from the vehicle.
  20.  
  21. Disconnect the fluid lines from the steering gear, pressure hose first.
  22.  
  23. Remove the steering gear clamp bolts securing the steering gear to the crossmember and remove the clamp. Remove the bolts that retain the steering gear bracket. Remove the steering gear and bracket from the vehicle.
  24.  

To install:

  1. Insert the steering gear into the crossmember. Be careful not to damage the gearbox boot.
  2.  
  3. Tighten the steering gear to the crossmember bracket to 44.1 ft. lbs.
  4.  
  5. Connect the fluid lines.
  6.  
  7. Align the cutout at the serrated section of the column shaft and yoke. Insert the universal joint into the column shaft.
  8.  
  9. Align the mating marks and insert the universal joint to serrated section of the steering gear assembly. Tighten the bolt to 17.4 ft. lbs.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Fill the power steering system with the proper grade and type fluid.
  14.  
  15. Start the engine and check for leaks. Correct as required.
  16.  

  1. Disconnect the negative battery cable.
  2.  
  3. Loosen the front wheel nut.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the tires and wheels.
  8.  
  9. Remove the front exhaust pipe assembly.
  10.  
  11. Remove the cotter pin and castle nut. Using a puller, remove the tie rod end from the knuckle arm.
  12.  
  13. Remove the jack up plate. Remove the front stabilizer.
  14.  
  15. Disconnect the power steering fluid pipe at the center of the gearbox and attach a vinyl hose. Discharge the fluid into a suitable container by turning the steering wheel fully clockwise and counterclockwise. Disconnect the other fluid line, and repeat the discharge procedure.
  16.  
  17. Remove the steering wheel. Make a matchmark on the universal joint. Remove the universal joint bolts and remove the joint from the vehicle.
  18.  
  19. Disconnect the fluid lines from the steering gear, return hose first.
  20.  
  21. Remove the steering gear clamp bolts securing the steering gear to the crossmember. Remove the steering gear from the vehicle.
  22.  

To install:

  1. Insert the steering gear into the crossmember. Be careful not to damage the gearbox boot.
  2.  
  3. Tighten the steering gear to the crossmember bracket to 43.0 ft. lbs.
  4.  
  5. Connect the fluid lines.
  6.  
  7. Align the cutout at the serrated section of the column shaft and yoke. Insert the universal joint into the column shaft.
  8.  
  9. Align the mating marks and insert the universal joint to serrated section of the steering gear assembly. Tighten the bolt to 17.4 ft. lbs.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  
  13. Fill the power steering system with the proper grade and type fluid.
  14.  
  15. Start the engine and check for leaks. Correct as required.
  16.  

Wrx



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Engine undercover
     

  4.  
  5. Remove the sub-frame as follows:
    1. Remove the bolt cover.
    2.  
    3. Remove the clip.
    4.  
    5. Loosen the sub-frame bolt (1) and leave it screwed in a few threads. Remove the remaining bolts in the following order: 2, 3, 4, 5 and 6. See illustration for bolt location.
    6.  

  6.  
  7. Remove or disconnect the following:

    Front exhaust pipe
     
    Tie rod end cotter pin and nut
     
    Tie rod ends from the steering knuckle using a puller
     
    Jack-up plate and front sway bar
     
    Fluid lines from the rack and pinion
     

  8.  
  9. Matchmark the universal joint to the serration in the steering rack for installation reference.

    Lower and upper universal joint bolts and lift the joint upward, disconnecting it from the rack and pinion shaft
     
    Clamp bolts securing the rack and pinion to the crossmember
     
    Rack and pinion
     

  10.  


    Click image to see an enlarged view

    Fig. Location of the sub-frame bolts-WRX models


To install:

  1. Install the rack and pinion. Tighten the clamp bolts to 43 ft. lbs. (59 Nm).
  2.  
  3. Align the steering rack to the universal joint. Push the long yoke of the joint all the way into the serrated position of the steering shaft, setting the bolt hole in the cut-out. Pull the short yoke all the way out of the serrated portion of the rack and pinion, setting the bolt hole in the cut-out. Insert the bolt through the short yoke. Pull the yoke and ensure the bolt is properly engaged in the cut-out. Fasten the short yoke side with the spring washer and bolt, then fasten the yoke side. Tighten the bolts to 19 ft. lbs. (27 Nm).
  4.  
  5. Install or connect the following:

    Tie rod ends to the steering knuckle
     
    Sway bar and jack-up plate
     

  6.  
  7. Install the sub-frame and bolts. Tighten the bolts as follows, referring to the illustration for location:
    1. T1: 25 ft. lbs. (34 Nm).
    2.  
    3. T2: 41 ft. lbs. (55 Nm).
    4.  
    5. T3: 52 ft. lbs. (71 Nm).
    6.  


      Click image to see an enlarged view

      Fig. Tighten the sub-frame bolts to the specification outlined in the procedure-WRX models

    7. Bolt and clip
    8.  
    9. Exhaust pipe with new gaskets and nuts
    10.  
    11. Engine undercover
    12.  
    13. Wheels
    14.  

  8.  
  9. Fill and bleed the steering system.
  10.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Engine undercover
     

  2.  
  3. Remove the sub-frame as follows:
    1. Remove the bolt cover.
    2.  
    3. Remove the clip.
    4.  
    5. Loosen the sub-frame bolt (1) and leave it screwed in a few threads. Remove the remaining bolts in the following order: 2, 3, 4, 5 and 6. See illustration for bolt location.
    6.  

  4.  
  5. Remove or disconnect the following:

    Front exhaust pipe
     
    Tie rod end cotter pin and nut
     
    Tie rod ends from the steering knuckle using a puller
     
    Jack-up plate and front sway bar
     
    Fluid lines from the rack and pinion
     

  6.  
  7. Matchmark the universal joint to the serration in the steering rack for installation reference.

    Lower and upper universal joint bolts and lift the joint upward, disconnecting it from the rack and pinion shaft
     
    Clamp bolts securing the rack and pinion to the crossmember
     
    Rack and pinion
     

  8.  

To install:

  1. Install the rack and pinion. Tighten the clamp bolts to 43 ft. lbs. (59 Nm).
  2.  
  3. Align the steering rack to the universal joint. Push the long yoke of the joint all the way into the serrated position of the steering shaft, setting the bolt hole in the cut-out. Pull the short yoke all the way out of the serrated portion of the rack and pinion, setting the bolt hole in the cut-out. Insert the bolt through the short yoke. Pull the yoke and ensure the bolt is properly engaged in the cut-out. Fasten the short yoke side with the spring washer and bolt, then fasten the yoke side. Tighten the bolts to 19 ft. lbs. (27 Nm).
  4.  
  5. Install or connect the following:

    Tie rod ends to the steering knuckle
     
    Sway bar and jack-up plate
     

  6.  
  7. Install the sub-frame and bolts. Tighten the bolts as follows, referring to the illustration for location:
    1. T1: 25 ft. lbs. (34 Nm).
    2.  
    3. T2: 41 ft. lbs. (55 Nm).
    4.  
    5. T3: 52 ft. lbs. (71 Nm).

      Bolt and clip
       
      Exhaust pipe with new gaskets and nuts
       
      Engine undercover
       
      Wheels
       

    6.  

  8.  
  9. Fill and bleed the steering system.
  10.  

 
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