1996 SUBARU LEGACY steering wheel

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]

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 exhaust pipe is hot.
3) Raise vehicle with a jack and remove front wheel.
4) Disconnect front exhaust pipe assembly.
G4M0097
5) Remove cotter pin and castle nut. Using a puller,
remove tie-rod end from knuckle arm.
G4M0098
6) Remove jack-up plate and stabilizer.
G4M0786
7) Disconnect one pipe joint A from center of gearbox
assembly, and connect a vinyl hose to it. While turning
steering wheel to the left and right, drain fluid through the
hose. Similarly, drain fluid from the other pipe joint B.
G4M0787
8) Remove lower and upper bolts from universal joint, and
remove universal joint in the upward direction.
NOTE:
Scribe alignment marks on universal joint so that it can be
reassembled at the original serration.
30
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

2) Adjust steering angle of wheels.
Standard of steering angle:
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 amount.
39
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

5. Control Valve (Power Steering
Gearbox) [LHD model]
NOTE:
This section focuses on the disassembly and reassembly
of control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to“Steering
Gearbox”.
G4M0136
1Power cylinder

2Cylinder

3Rack piston

4Rack axle

5Input shaft
6Torsion bar

7Valve housing

8Valve body

9Control valve
10Pipe B

11Pipe A

12Pinion

13Pinion axle
A: CHECKING OIL LEAKING POINTS
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform check
step 5) in 4-3 [W5A2] before dismounting gearbox from
vehicle. If gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the leak
point.
2) Even if the location of the leak can be easily found by
observing the leaking condition, it is necessary to thor-
oughly remove the oil from the suspected portion and turn
the steering wheel from lock to lock about 30 to 40 times
with engine running, then make comparison of the sus-
pected portion between immediately after and several
hours after this operation.
3) Before starting oil leak repair work, be sure to clean the
gearbox, hoses, pipes, and surrounding parts. After com-
pleting repair work, clean these areas again.
40
4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

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”
The cylinder seal is damaged. Replace rack bush with a
new one.
7) Leakage from“f”
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“f”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“f”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
41
4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

6. Control Valve (Power Steering
Gearbox) [RHD model]
NOTE:
This section focuses on the disassembly and reassembly
of control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to“Steering
Gearbox”.
B4M0668A
A: CHECKING OIL LEAKING POINTS
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform check
step 5) in 4-3 [W6A2] before dismounting gearbox from
vehicle. If gearbox is dismounted without confirming where
the leak is, it must be mounted again to locate the leak
point.
2) Even if the location of the leak can be easily found by
observing the leaking condition, it is necessary to thor-
oughly remove the oil from the suspected portion and turn
the steering wheel from lock to lock about 30 to 40 times
with engine running, then make comparison of the sus-
pected portion between immediately after and several
hours after this operation.
3) Before starting oil leak repair work, be sure to clean the
gearbox, hoses, pipes, and surrounding parts. After com-
pleting repair work, clean these areas again.
49
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

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]

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]