1996 SUBARU LEGACY steering

2. OIL LEAK CHECK PROCEDURE AND
REPLACEMENT PARTS
NOTE:
Parts requiring replacement are described in the smallest
unit of spare parts including damaged parts and spare
parts damaged. In actual disassembly work, accidental
damage as well as inevitable damage to some related
parts must be taken into account, and spare parts for them
must also be prepared. However, it is essential to pinpoint
the cause of trouble, and limit the number of replacement
parts as much as possible.
1) Leakage from“a”
The oil seal is damaged. Replace valve assembly with a
new one.
2) Leakage from“b”
The torsion bar O-ring is damaged. Replace valve assem-
bly with a new one.
3) Leakage from“c”
The oil seal is damaged. Replace valve assembly with a
new one.
4) Leakage from“d”
The pipe is damaged. Replace the faulty pipe or O-ring.
5) If leak is other than a, b, c, or d, and if oil is leaking from
the gearbox, move the right and left boots toward tie-rod
end side, respectively, with the gearbox mounted to the
vehicle, and remove oil from the surrounding portions.
Then, turn the steering wheel from lock to lock 30 to 40
times with the engine running, then make comparison of
the leaked portion immediately after and several hours
after this operation.
6) Leakage from“e”
There are two possible causes. Take following step first.
Remove the pipe assembly B from the valve housing, and
close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to 40 times
with the engine running, then make comparison of the
leaked portion between immediately after and several
hours after this operation.
CAUTION:

If leakage from“e”is noted again:
The oil seal of pinion and valve assembly is damaged.
Replace pinion and valve assembly with a new one. Or
replace the oil seal and the parts that are damaged
during disassembly with new ones.

If oil stops leaking from“e”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
50
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0817
B: DISASSEMBLY
1. VALVE ASSEMBLY
1) Slide dust cover out.
CAUTION:

Be careful not to scratch housing or input shaft dur-
ing dust cover removal. Also do not allow foreign mat-
ter to enter housing interior.

Replace dust cover with a new one if its inside bore
or lips are worn or damaged.
G4M0818
2) Remove the two bolts securing valve housing.
G4M0819
3) Remove valve housing, pinion and valve as a unit.
G4M0820
2. RACK ASSEMBLY
1) Remove holder using a 32 mm (1.26 in) wrench or
adjustable wrench.
CAUTION:
Discard old holder and replace with new one.
51
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0821
2) Install ST on valve side of rack and press outer side oil
seal out.
ST 34099FA030 INSTALLER & REMOVER
CAUTION:

Block pipe connection of steering body to prevent
fluid from flowing out.

Do not allow rack to come in contact with inner wall
of cylinder. Otherwise, cylinder wall may be scratched,
resulting in oil leaks.

Remove holder and rack as a unit.

Check rack and steering body for bends or cracks
and replace as required.

Discard oil seal after removal and replace with new
ones.
G4M0822
3) Insert ST from valve side and press back-up ring and oil
seal out.
CAUTION:
Discard back-up ring and oil seal after removal and
replace with new ones.
ST 927580000 REMOVER
52
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0823
4) Using ST1 and ST2, repair cylinder’s clinched sections.
ST1 34099FA080 PUNCH
ST2 34099FA070 BASE
G4M0889
5) If cylinder edge is deformed in a convex shape, repair
using an oil stone.
G4M0824
C: REPLACEMENT OF SEAL AND PACKING
1. VALVE HOUSING OIL SEAL

Removal
1) After removing dust cover, extract pinion and valve from
valve housing.
CAUTION:

If pinion and valve is difficult to remove, use a press.

Discard Y-packing after removal and replace with a
new one.

Check rotor for bends and serrations for damage
and replace as required.
53
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0825
2) Using ST and press, remove dust seal, back-up washer,
Y-packing and ball bearing from valve housing.
CAUTION:

Use the“A”end of remover.

Do not apply a force to end surface of valve hous-
ing.

Do not reuse Y-packing after removal.
ST 34099FA000 INSTALLER & REMOVER
G4M0836

Installation
Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
1) Apply a coat of grease to inner wall of valve housing,
Y-packing and outer perimeter of dust seal.
G4M0838
2) Using ST and press, install Y-packing in valve housing.
(1) Face Y-packing in the direction shown in figure
when installing.
(2) To avoid scratching Y-packing, apply a coat of
grease to contact surface of installer and Y-packing.
(3) To facilitate installation, attach Y-packing to installer
and position in valve housing before pressing into
place.
ST 34099FA000 INSTALLER & REMOVER
G4M0839
3) Attach ST2 to ST1, and press ball bearing into place
using a press.
NOTE:

To facilitate installation, attach ball bearing to remover
and position in valve housing before pressing it into place.

Use the“B”end of remover.
ST1 34099FA000 INSTALLER & REMOVER
ST2 34099FA050 SPACER
G4M0840
4) Charge Y-packing with specified steering grease.
54
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0841
5) Apply a coat of specified steering grease to ST surface,
and install ST onto end of input shaft. Insert pinion and
valve until“A”of oil seal contacts“B”of valve housing. The
ST is used to prevent scratching Y-packing.
ST 34099FA020 GUIDE
G4M0842
6) While supporting pinion and valve, push end of pinion
until bearing contacts brazed end of valve housing.
CAUTION:
Do not allow spacer to extend beyond brazed end.
Otherwise, pinion cannot be inserted properly.
G4M0843
7) Apply a coat of grease to sealing lips of dust cover, and
insert dust cover until it contacts staged portion of input
shaft.
8) Adjust sealing lip-to-housing end clearance to 0 to 0.5
mm (0 to 0.020 in). If sealing lip is too close to housing end,
steering wheel will not return smoothly; if it is too far from
housing end, dust or dirt will enter the clearance.
NOTE:
Ensure that pinion and valve is properly positioned in valve
housing before adjustment.
G4M0826
2. PINION AND VALVE ASSEMBLY

Removal
1) Remove snap ring securing valve sleeve to pinion and
valve, and remove valve sleeve.
CAUTION:
Be careful not to scratch pinion and valve when remov-
ing snap ring.
G4M0827
2) Remove oil seal and spacer.
3) Using a long rod, remove seal ring and O-ring from
pinion.
CAUTION:
Be careful not to scratch outer surface and seal ring
groove of input shaft. If scratched, sealing effect will
be lost, resulting in a malfunctioning valve.
55
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0828

Installation
1) Wash and clean pinion & valve and valve housing.
2) Attach ST to pinion, and apply grease to outer perimeter
of the cover and mating surface of oil seal.
ST 926270000 COVER
G4M0829
3) Apply a coat of grease to spacer and sealing lips of oil
seal, and install spacer and oil seal.
CAUTION:

Face chamfered side of spacer toward oil seal.

Face oil seal in correct direction.
G4M0830
4) Install ST to input shaft, and apply a coat of grease to
the cover surface. Install O-ring and seal ring.
CAUTION:
Do not expand O-ring and seal ring more than neces-
sary.
ST 926450000 COVER
G4M0831
5) Apply a coat of grease to inner wall of ST, and secure
seal ring assembled in step 4) as shown. Leave seal ring
unattended for approximately 10 minutes until it settles
down.
ST 926280000 FORMER
G4M0832
6) While aligning valve sleeve pin with groove on pinion,
secure with snap ring.
CAUTION:

Be careful not to damage inner wall of valve sleeve
and contact surface of pinion.

Before assembling valve sleeve and pinion, clean in
kerosene and dry with compressed air.
56
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0833
3. RACK PISTON SEAL RING AND O-RING

Removal
Using a sharp-edged, long rod, remove seal ring and
O-ring from rack piston.
CAUTION:
Be careful not to scratch outer surface of rack piston
and seal ring groove. A scratch may reduce the seal-
ing effect, resulting in faulty piston operation.
G4M0834

Installation
1) Wash clean rack piston.
2) Install O-ring and seal ring in groove on rack piston.
CAUTION:

Do not expand O-ring and seal ring more than nec-
essary.

To facilitate installation of seal ring, first position
one half of entire seal ring in groove. Then slowly posi-
tion the second half using a spatula, as shown.
G4M0835
3) Apply a coat of grease to inner surface of ST and insert
rack piston into it. Leave ST at least 10 minutes until seal
ring settles down in place.
CAUTION:
Be careful not to scratch rack, piston and seal ring
during installation.
ST 927600000 FORMER
57
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]