1995 SUBARU LEGACY boot

6. Replacement of Rear DOJ and BJ
Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and wheels.
NOTE:
Axle nut need not be removed.
3) Remove A.B.S. sensor clamps and parking brake cable
bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assembly to rear
housing.
6) Remove bolts which secure trailing link assembly to
rear housing.
7) Remove crossmember reinforcement lower from cross-
member (4 door model only).
G4M0994
8) Remove DOJ from rear differential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
NOTE:
The side spline shaft circlip comes out together with the
shaft.
G4M0995
CAUTION:
Be careful not to damage side bearing retainer. Always
use bolt as shown in figure, as supporting point for ST
during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
B: INSTALLATION
1) Install DOJ and BJ boots to drive shaft.

42
4-2SERVICE PROCEDURE
6. Replacement of Rear DOJ and BJ Boots

B4M0549A
2) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
B4M0550A
3) Insert DOJ spline end into bore of side oil seal, and
remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil seal.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M0050
4) Align DOJ and differential splines.
5) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
CAUTION:
Discard old self-locking nut. Replace with a new one.
6) Connect rear housing assembly to trailing link
assembly, and tighten self-locking nut.
7) Connect rear housing assembly to lateral link assembly,
and tighten self-locking nut.
8) Connect stabilizer link to lateral link.
9) Install crossmember reinforcement lower to crossmem-
ber (4 door model only).
10) Install A.B.S. sensor clamps and parking brake cable
bracket.
43
4-2SERVICE PROCEDURE
6. Replacement of Rear DOJ and BJ Boots

1Clamp

2Adapter

3Hose bracket

4Pipe C

5Pipe D

6Cap

7Strainer

8Tank

9Oil pump

10Pulley

11Belt cover

12Bracket

13Pipe E

14Clamp plate

15Pipe F

16Universal joint

17Dust seal

18C-ring

19Oil seal

20Valve housing

21Packing

22Seal ring

23Pinion and valve ASSY

24Oil seal

25Back-up washer

26Ball bearing

27Snap ring

28Sleeve
29Spring

30Adjusting screw

31Lock nut

32Housing ASSY

33Back-up washer

34Oil seal

35Adapter

36Clamp

37Pipe A

38Pipe B

39Lock washer

40Tie-rod

41Boot

42Cotter pin

43Castle nut

44Dust seal

45Tie-rod end

46Spacer

47Circlip

48Rack stopper

49Oil seal

50Rack bushing

51O-ring

52Rack

53Piston ring

54Seal washer

55O-ring
6
4-3COMPONENT PARTS
2. Power Steering System

1Pipe C

2Pipe D

3Cap

4Strainer

5Tank

6Pulley

7Oil pump

8Bracket

9Belt cover

10Universal joint

11Dust cover

12Valve housing

13Y-packing

14Ball bearing

15Spacer

16Pinion

17Shim

18Cotter pin

19Castle nut

20Dust seal

21Clip

22Tie-rod end

23Clip

24Boot
25Wire

26Tie-rod RH

27Lock washer

28Lock nut

29Adjusting screw

30Spring

31Sleeve

32Pipe B

33Pipe A

34Housing ASSY

35Adapter

36Clamp

37Back-up washer

38Oil seal

39Rack

40O-ring

41Oil seal

42Y-packing

43Bush

44Holder

45Tie-rod LH

46O-ring

47Seal washer
8
4-3COMPONENT PARTS
2. Power Steering System

3. Steering Gearbox (Power Steering
System) [LHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0131A
1Cotter pin

2Castle nut

3Dust cover

4Clip

5Tie-rod end

6Clip

7Boot

8Clip

9Spacer

10Tie-rod

11Lock washer

12Circlip

13Rack stopper

14Oil seal

15Rack bushing
16O-ring

17Rack

18Back-up washer

19Rack housing

20Adapter

21Clamp

22Lock nut

23Adjusting screw

24Spring

25Sleeve

26C-ring

27Ball bearing

28Valve

29Seal ring

30Packing
31Valve housing

32Dust seal

33Universal joint

34Spring washer
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 24±3 (2.4±0.3, 17.4±2.2)
T3: 25±5 (2.5±0.5, 18.1±3.6)
T4: 27.0±2.5
(2.75±0.25, 19.9±1.8)
T5: 39±10 (4.0±1.0, 29±7)
T6: 59±12 (6.0±1.2, 43±9)
T7: 78±10 (8.0±1.0, 58±7)
T8: 83±5 (8.5±0.5, 61.5±3.6)
15
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0101
9) Disconnect pipes C and D from pipe of gearbox.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect upper pipe D first, and lower pipe C second.
G4M0102
10) Remove clamp bolts securing gearbox to
crossmember, and remove gearbox.
B4M0132A
B: DISASSEMBLY
1) Disconnect four pipes from gearbox.
2) Secure gearbox removed from vehicle in vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox in a vice using the ST as shown.
Do not attempt to secure it without this ST.
3) Remove tie-rod end and lock nut from gearbox.
G4M0104
4) Remove small clip from boot using pliers, and move
boot to tie-rod end side.
G4M0105
5) Remove boot together with large clips.
17
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

C: INSPECTION
1) Clean all disassembled parts, and check for wear,
damage, or any other faults, then repair or replace as nec-
essary.
2) When disassembling, check inside of gearbox for water.
If any water is found, carefully check boot for damage,
input shaft dust seal, adjusting screw and boot clips for
poor sealing. If faulty, replace with new parts.
No. Parts Inspection Corrective action
1 Input shaft(1) Bend of input shaft
(2) Damage on serrationIf bend or damage is excessive, replace
entire gearbox.
2 Dust seal(1) Crack or damage
(2) WearIf outer wall slips, lip is worn out or
damage is found, replace it with new one.
3 Rack and pinion Poor mating of rack with pinion(1) Adjust backlash properly.
By measuring turning torque of
gearbox and sliding resistance of rack,
check if rack and pinion engage
uniformly and smoothly with each
other.
(Refer to“Service limit”.)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for
damage.
Even if abnormality is found in either
(1) or (2), replace entire gearbox.
4 Gearbox unit(1) Bend of rack shaft
(2) Bend of cylinder portion
(3) Crack or damage on cast iron portionReplace gearbox with new one.
(4) Wear or damage on rack bushIf free play of rack shaft in radial direction
is out of the specified range, replace
gearbox with new one. (Refer to“Service
limit”.)
(5) Wear on input shaft bearingIf free plays of input shaft in radial and
axial directions are out of the specified
ranges, replace gearbox with new one.
(Refer to“Service limit”.)
5 Boot Crack, damage or deterioration Replace.
6 Tie-rod(1) Looseness of ball joint
(2) Bend of tie-rodReplace.
7 Tie-rod end Damage or deterioration on dust seal Replace.
8 Adjusting screw spring Deterioration Replace.
9 Boot clip Deterioration Replace.
10 Sleeve Damage Replace.
11 Pipes(1) Damage to flared surface
(2) Damage to flare nut
(3) Damage to pipe
(4) Damage to O-ringReplace.
19
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

Make adjustment so that steering wheel can be rotated
fully from lock to lock without binding.
9) Check for service limit as per article of“Service limit”.
Make replacement and adjustment if
necessary.
10) Install boot and mounting rubber to housing.
NOTE:
Apply grease through small hole in boot.
G4M0123
11) Fit clip (large) to boot, and then install boot to gearbox
while holding boot flange.
After installing boot, fold back boot flange to the extent that
large clip can not be seen.
NOTE:

Before installing boot, be sure to apply grease to the
groove of tie-rod.

Install fitting portions of boots to the following portions in
both sides of assembled steering gearbox.
1. The groove on gearbox
2. The groove on the rod

Make sure that boot is installed without unusual inflation
or deflation.
G4M0124
12) Turn boot until it seats well on gearbox and rubber
mounting, then bend boot flange back.
G4M0125
13) Fix boot end with clip (small).
CAUTION:
Use screwdriver with blunted tip to prevent boot from
damage, when installing.
NOTE:
After installing, check boot end is positioned into groove on
tie-rod.
24
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]