Page 1129 of 2890

G4M0116
4) Press-fit dust seal into gearbox housing while tapping it
via a spanner or the like so that stepping between gearbox
and dust seal is normally 2 mm (0.08 in).
G4M0117
Depth: A
2 mm (0.08 in)
G4M0118
5) Apply grease to sliding surface of sleeve and spring
seat, then insert sleeve into pinion housing. Fit spring into
sleeve screw, pack grease inside of screw, then install the
screw.
1Sleeve
2Spring
3Adjusting screw
G4M0107
6) Fit new lock washer on screwed portion of rack end.
Aligning cut portion of rack and nail of washer, screw in and
tighten ball joint by using ST and spanner.
ST 925700000 WRENCH
Tightening torque (Ball joint):
78±10 N⋅m (8.0±1.0 kg-m, 58±7 ft-lb)
CAUTION:
Pay attention to prevent rack surface on the right side
from being damaged by a tool or the like, otherwise oil
leakage might be caused.
NOTE:
While tightening ball joint, hold rack with ST to prevent it
from revolving.
22
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]
Page 1130 of 2890
G4M0120
7) Bend lock washer using a chisel.
CAUTION:
Be careful not to scratch rack when bending lock
washer.
G4M0122
8) Rack and pinion backlash adjustment
(1) Loosen adjusting screw.
(2) Rotate input shaft so that rack is in the straight
ahead direction.
(3) Apply grease to sleeve.
1Sleeve
2Spring
3Lock nut
4Adjusting screw
G4M0121
(4) Tighten adjusting screw by two threads.
G4M0662
(5) Apply liquid packing to at least 1/3 of entire perim-
eter of adjusting screw thread.
Liquid packing:
THREE BOND 1141
(6) Tighten adjusting screw to 15 N⋅m (1.5 kg-m, 11
ft-lb) and back off 26°.
(7) Install lock nut. While holding adjusting screw with
a wrench, tighten lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
39±10 N⋅m (4.0±1.0 kg-m, 29±7 ft-lb)
NOTE:
Hold adjusting screw with a wrench to prevent it from
turning while tightening lock nut.
23
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]
Page 1131 of 2890
![SUBARU LEGACY 1996 Service Repair Manual 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”.
<Ref. to 4-3 [W3C1].> Make replacement SUBARU LEGACY 1996 Service Repair Manual 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”.
<Ref. to 4-3 [W3C1].> Make replacement](/manual-img/17/57433/w960_57433-1130.png)
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]
Page 1132 of 2890

G4M0126
14) If tie-rod end was removed, screw in lock nut and tie-
rod end to screwed portion of tie-rod, and tighten lock nut
temporarily in a position as shown in figure.
Installed tie-rod length: L
15 mm (0.59 in)
NOTE:
Pay attention to difference between right and left tie-rod
ends.
G4M0127
15) Inspect gearbox as follows:
A. Holding tie-rod end, repeat lock to lock two or three
times as quickly as possible.
B. Holding tie-rod end, turn it slowly at a radius one or two
times as large as possible.
After all, make sure that boot is installed in the specified
position without deflation.
16) Remove gearbox from ST.
ST 926200000 STAND
17) Install four pipes on gearbox.
(1) Connect pipes A and B to four pipe joints of gear-
box. Connect upper pipe B first, and lower pipe A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
G4M0101
(2) Connect pipes C and D to gearbox.
Connect lower pipe C first, and upper pipe D second.
Tightening torque:
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
G4M0102
E: INSTALLATION
1) Insert gearbox into crossmember, being careful not to
damage gearbox boot.
2) Tighten gearbox to crossmember bracket via clamp with
bolt to the specified torque.
Tightening torque:
59±12 N⋅m (6.0±1.2 kg-m, 43±9 ft-lb)
25
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]
Page 1133 of 2890

3) How to install the joint.
(1) Push the long yoke of the joint, all the way into the
serrated portion of the steering shaft, setting the bolt
hole in the cutout.
(2) Then pull the short yoke all way out of the serrated
portion of the gearbox, setting the bolt hole in the cut-
out.
(3) Insert the bolt through the short yoke, pull the joint
and confirm that the bolt is on cutout of the gearbox.
G4M0086
(4) Fasten the short yoke side with a spring washer
and bolt, then fasten the long yoke side.
Tightening torque:
24±3 N⋅m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
G4M0097
4) Connect tie-rod end and knuckle arm, and tighten with
castle nut. Fit cotter pin into the nut and bend the pin to
lock.
Castle nut tightening torque:
Tighten to 27.0±2.5 N⋅m (2.75±0.25 kg-m,
19.9±1.8 ft-lb), and tighten further within 60°until
cotter pin hole is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit cap at the bottom of tie-
rod end with hammer.
5) Install front stabilizer to vehicle.
6) Install front exhaust pipe assembly.
7) Install tires.
8) Tighten wheel nuts to the specified torque.
Tightening torque:
88±10 N⋅m (9.0±1.0 kg-m, 65±7 ft-lb)
9) Connect ground cable to battery.
10) Pour fluid into oil tank, and bleed air.
[W10A0].>
11) Check for fluid leaks.
12) Install jack-up plate.
WARNING:
Be careful, exhaust manifold is hot.
13) Lower vehicle.
14) Check fluid level in oil tank.
26
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]
Page 1134 of 2890
G4M0132
15) After adjusting toe-in and steering angle, tighten lock
nut on tie-rod end.
Tightening torque:
83±5 N⋅m (8.5±0.5 kg-m, 61.5±3.6 ft-lb)
CAUTION:
When adjusting toe-in, hold boot as shown to prevent
it from being rotated or twisted. If twisted, straighten it.
G4M0133
F: ADJUSTMENT
1) Adjust front toe.
Standard of front toe:
IN 3—OUT 3 mm (IN 0.12—OUT 0.12 in)
2) Adjust steering angle of wheels.
Inner wheel: 37.6°±1.5
Outer wheel: 32.6°±1.5
B4M0133A
3) If steering wheel spokes are not horizontal when wheels
are set in the straight ahead position, and error is more
than 5°on the periphery of steering wheel, correctly re-in-
stall the steering wheel.
G4M0135
4) If steering wheel spokes are not horizontal with vehicle
set in the straight ahead position after this adjustment,
correct it by turning the right and left tie-rods in the same
direction by the same turns.
27
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]
Page 1135 of 2890
4. Steering Gearbox (Power Steering
System) [RHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0666A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 20±4 (2.0±0.4, 14.5±2.9)
T2: 25±5 (2.5±0.5, 18.1±3.6)
T3: 39±10 (4.0±1.0, 29±7)
T4: 64±10 (6.5±1.0, 47±7)
T5: 78±10 (8.0±1.0, 58±7)
T6: 83±5 (8.5±0.5, 61.5±3.6)
28
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]
Page 1136 of 2890
1Dust cover
2Valve housing
3Y-packing
4Ball-bearing
5Spacer
6Pinion
7Shim
8Dust seal
9Clip
10Tie-rod end
11Clip
12Boot
13Wire
14Tie-rod RH
15Lock washer
16Sleeve
17Spring
18Adjusting screw
19Lock nut
20Pipe A
21Pipe B
22Adapter
23Housing ASSY
24Back-up washer
25Oil seal
26Rack
27O-ring
28Oil seal
29Y-packing
30Bush
31Holder
32Tie-rod LH
29
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]