1995 SUBARU LEGACY light

B4M0227A
13) Put 80 to 90 g (2.82 to 3.17 oz) of specified grease into
the interior of DOJ outer race.
14) Apply a coat of specified grease to the cage pocket
and six balls.
15) Insert six balls into the cage pocket.
16) Align the outer race track and ball positions and place
in the part where shaft, inner race, cage and balls are pre-
viously installed, and then fit outer race.


1Outer race


2Grease
G4M0282
17) Install circlip in the groove on DOJ outer race.
NOTE:
Assure that the balls, cage and inner race are com-
pletely fitted in the outer race of DOJ.
Exercise care not to match the open end of circlip in the
ball groove of outer race.
Pull the shaft lightly and assure that the circlip is com-
pletely fitted in the groove.
18) Apply an even coat of specified grease [20 to 30 g
(0.71 to 1.06 oz)] to the entire inner surface of boot. Also
apply grease to shaft.
19) Install DOJ boot taking care not to twist it.
NOTE:
The inside of the larger end of DOJ boot and the boot
groove shall be cleaned so as to be free from grease and
other substances.
When installing DOJ boot, position outer race of DOJ at
center of its travel.
20) Put a band through the clip and wind twice in align-
ment with band groove of boot.
CAUTION:
Use a new band.
21) Pinch the end of band with pliers. Hold the clip and
tighten securely.
NOTE:
When tightening boot, exercise care so that the air within
the boot is appropriate.
G4M0289
22) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
37
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

B4M0561A
10) Place oil pump in a vise, remove two bolts from oil tank
and detach oil tank.
CAUTION:
Do not place oil pump directly in the vise; use soft
pads and hold oil pump lightly to protect the pump.
B: CHECK
In accordance with the following table, check all removed
parts for wear and damage, and make repair or replace-
ment if necessary.
No. Parts Inspection Corrective action
1 Oil pump (Exterior)(1) Crack, damage or oil leakage Replace oil pump with a new one.
(2) Play of pulley shaftMeasure radial play and axial play.
If any of these exceeds the service limit,
replace oil pump with a new one. [W8B1].>
2 Pulley(1) Damage Replace it with a new one.
(2) BendMeasure V ditch deflection.
If it exceeds the service limit, replace
pulley with a new one.
3 Cap Crack or damage Replace it with a new one.
4 Strainer(1) Clogging with dirt Wash it.
(2) Breakage Replace it with a new one.
5 Oil pump (Interior)(1) Defect or burning of vane pumpCheck resistance to rotation of pulley.
If it is past the service limit, replace oil
pump with a new one.
(2) Bend in the shaft or damage to
bearingOil pump emits a noise that is markedly
different in tone and loudness from a
sound of a new oil pump when turning with
a string put around its pulley, replace oil
pump with a new one.
6 O-ring Crack or deterioration Replace it with a new one.
7 Oil tank Crack, damage or oil leakage Replace it with a new one.
8 Bracket Crack or damage Replace it with a new one.
73
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

C: DISASSEMBLY
B4M0142A
1Pulley

2Snap ring

3Bearing

4Oil seal

5Shaft

6Connector

7O-ring

8Spool valve
9Spring

10Front casing

11Rear cover

12Knock pin

13Seal washer

14Cam ring

15Vane

16Rotor
17Side plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 16±2 (1.6±0.2, 11.6±1.4)
T2: 61±7 (6.2±0.7, 45.0±5.2)
T3: 74±5 (7.5±0.5, 54.2±3.6)
B4M0561A
1) Oil pump body
(1) Place oil pump in a vise, and remove two bolts
which secure tank.
CAUTION:
Do not place oil pump directly in vise; use soft pads
and hold oil pump lightly to protect it.
75
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

G4M0178
(2) Remove four bolts which secure rear cover.
G4M0923
(3) Remove the following parts from front casing.

1Seal washer

2Knock pin ...............................................................2 ea.

3Cam ring

4Rotor

5Vane .....................................................................10 ea.

6Side plate

7O-ring .....................................................................2 ea.
CAUTION:
Discard old seal washer; replace with a new one.
G4M0180
2) Control valve
Slightly loosen outlet connector, and remove connector.
Remove the following parts for pump casing.

Spool valve assembly

Flow control spring

Connector

O-ring
G4M0181
3) Shaft
(1) Remove snap ring from front casing.
76
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

G4M0182
(2) Remove shaft using a hand press.
CAUTION:

Discard old drive shaft assembly; replace with a new
one.

Be careful not to scratch or dent casing’s surface
which serves as a seal.
G4M0183
(3) Pry oil seal off using a screwdriver.
CAUTION:
Be careful not to scratch inner surface of casing.
4) Remove pressure switch.
D: INSPECTION
Perform the following inspection procedures and repair or
replace defective parts.
Part name Description Remedy
1. Front casing1) Damage on body surfaces
2) Excessive wear on hole, into which spool valve
is inserted.
3) Wear and damage on cartridge assembly mount-
ing surface
4) Wear and damage on surfaces in contact with
shaft and oil sealReplace with a new one together with spool valve
as selective fit is made.
2. Rear cover1) Damage on body surfaces
2) Wear and damage on sliding surfacesReplace with a new one.
3. Shaft1) Shaft bend
2) Wear and damage on surfaces in contact with
bushing and oil seal
3) Wear and damage on rotor mounting surfaces
4) Bearing damageReplace with a new one.
4. Side plate Wear and damage on sliding surfaces Replace with a new one.
5. Cam ring Ridge wear on sliding surfaces
If damage is serious, replace with a new cartridge
assembly. 6. Vane Excessive wear on nose radius and side surfaces
7. Rotor1) Wear and damage on sliding surfaces
2) Ridge wear on vane sliding grooves (If light
leaks with vane in slit against light source)
3) Damage resulting from snap ring removalCorrect with oil stone. If damage is serious, replace
with a new cartridge assembly.
8. Spool valve Damage or burrs on sliding surface peripheryReplace with a new one together with front casing
as selective fit is made.
9. Connector Damage on threads Replace with a new one.
10. Spring Damage Replace with a new one.
11. Bolts and nuts Damage on threads Replace with a new one.
77
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

6) Check
(1) When reassembly procedures have been
completed, turn shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign mat-
ter trapped on sliding surfaces and improper installa-
tion. Eliminate the cause of trouble.
(2) Check followings by referring to“CHECK”article.

Excessive play in pulley shaft

Ditch deflection of pulley

Resistance to rotation of pulley

Measurement of generated oil pressure
F: INSTALLATION
1) Install bracket on engine.
Tightening torque:
22±2 N⋅m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
2) Install oil pump on oil tank as follows outside the
vehicle:
NOTE:
Prior to installation, make sure that all oil is removed from
oil pump, oil tank and pipe.
B4M0562A
3) Place oil pump in vise.
CAUTION:
Do not place oil pump directly in vise; use soft pads
and hold oil pump lightly to protect it.
4) Install oil tank on oil pump.
Tightening torque:
Bolt C: 15.7±2.4 N⋅m
(1.60±0.24 kg-m, 11.58±1.77 ft-lb)
Bolt D: 18.1±2.5 N⋅m
(1.85±0.25 kg-m, 13.35±1.84 ft-lb)
CAUTION:
Discard old seal washer and replace with a new one.
80
4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)

Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.Loosened installation of oil pump,
oil pump bracketRetighten.
*8
Abnormal inside of oil pump, hoseReplace oil pump, hose, if the
noise can be heard when running
as well as stand still.
Torque converter growl
air conditioner compression growlRemove power steering pulley
belt and confirm.
Creaking noise (intermittent)
While engine is running with
steering turned.Abnormal inside of gearboxReplace bad parts of gearbox.
Abnormal bearing for steering
shaftApply grease or replace.
*9
Generates when turning steering
wheel with brake (service or park-
ing) applied.If the noise goes off when brake
is released, it is normal.
*10
Vibration
While engine is running with/
without steering turned.
Too low engine speed at startAdjust and instruct customers.
Vane pump aerationFix wrong part.
Vent air.
Damaged valve in oil pump, gear-
boxReplace oil pump, bad parts of
gearbox.
Looseness of play of steering,
suspension partsRetighten.
*8 Oil pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when steering wheel
is turned at stand still there is no abnormal function in the system provided that the noise eliminates when the vehicle is
running.
*9 When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light
steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between
the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.
*10 There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the com-
ponent parts are properly adjusted and have no defects.
Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of com-
bined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature
and braking condition.
This phenomena does not indicate there is some abnormal function in the system.
The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step
with parking brake applied on concrete road and in“D”range for automatic transmission vehicle.
97
4-3DIAGNOSTICS
1. Power Steering

9. BREAKAGE OF HOSES
Pressure hose burstExcessive holding time of relief
statusInstruct customers.
Malfunction of relief valveReplace oil pump.
Poor cold characteristic of fluidReplace fluid.
Forced out return hosePoor connectionCorrect.
Poor holding of clipRetighten.
Poor cold characteristic of fluidReplace fluid.
Fluid bleeding out of hose slightlyWrong layout, tensionedReplace hose.
Excessive play of engine due to
deterioration of engine mounting
rubberReplace defective parts.
Improper stop position of pitching
stopperReplace defective parts.
*11
Crack on hose
Excessive holding time of relief
statusReplace.
Instruct customer.
Excessive tightening torque for
return hose clipReplace.
Power steering fluid, brake fluid,
engine oil, electrolyte adhere on
the hose surfaceReplace.
Pay attention on service work.
Too many times use in extremely
cold weatherReplace.
Instruct customers.
*11 Although surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for
low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and
automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free
from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or
cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspec-
tion frequently when the vehicle is used in hot weather areas, cold weather area and/or a driving condition in which many
steering operations are required in short time. Particularly continuous work of relief valve over 5 seconds causes to reduce
service lives of the hoses, the oil pump, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
100
4-3DIAGNOSTICS
1. Power Steering