1996 SUBARU LEGACY Service Repair Manual

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Page 1137 of 2890

SUBARU LEGACY 1996 Service Repair Manual A: REMOVAL
1) Disconnect battery negative terminal.
2) Disconnect both oxygen sensor and exhaust gas tem-
perature warning sensor connectors from front exhaust
pipe assembly.
WARNING:
Be careful as ex

Page 1138 of 2890

SUBARU LEGACY 1996 Service Repair Manual 9) Remove flare nuts from control valve of gearbox
assembly, and disconnect upper and lower hoses B and A.
CAUTION:
Always disconnect hoses B and A in that order.
Be careful not to damage the hoses

Page 1139 of 2890

SUBARU LEGACY 1996 Service Repair Manual G4M0792
6) Using ST, loosen lock nut.
ST 926230000 SPANNER
G4M0793
7) Tighten adjusting screw until it no longer tightens.
G4M0794
8) Using a wrench [32 mm (1.26 in) width across flats] or
adjustable

Page 1140 of 2890

SUBARU LEGACY 1996 Service Repair Manual 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

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.
33
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

Page 1141 of 2890

SUBARU LEGACY 1996 Service Repair Manual G4M0796
G4M0797
1. SERVICE LIMIT
Make a measurement as shown in the figures. If it exceeds
the specified service limit, adjust or replace.
NOTE:
When making a measurement, vise gearbox by using ST.
Ne

Page 1142 of 2890

SUBARU LEGACY 1996 Service Repair Manual G4M0801
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
On condition
P: 20—49N(2—5 kg, 4—11 lb)
G4M0802
4. TURNING RESISTANCE OF GEARBOX
Using ST, measure gearbox turning resistanc

Page 1143 of 2890

SUBARU LEGACY 1996 Service Repair Manual G4M0803
4) Apply a coat of grease to sliding surface of sleeve and
seating surface of spring, and insert sleeve into steering
body. Charge adjusting screw with grease, insert spring
into adjusting scr

Page 1144 of 2890

SUBARU LEGACY 1996 Service Repair Manual G4M0662
(4) Turn adjusting screw so that the entire thread area
is coated with liquid packing.
Liquid packing:
THREE BOND 1102 or equivalent
NOTE:
Apply liquid packing of approximately 1.5 grams (0.0

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