1996 SUBARU LEGACY power steering

G4M0850
9) Attach ST to rack cylinder. Using a press, install
back-up ring and oil seal.
NOTE:
Press ST until its groove is aligned with end of holder.
ST 34099FA030 INSTALLER & REMOVER
G4M0967
10) Using ST, clinch steering body cylinder at a point less
than 3 mm (0.12 in) from holder.
CAUTION:
Be careful not to deform holder.
ST 34099FA060 PUNCH HOLDER
60
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

B4M0669A
2. VALVE ASSEMBLY
1) Remove traces of sealer, oil, rust, etc., from mating
surfaces of valve housing and steering body.
2) Position a shim in graded portion of steering body pin-
ion housing, and apply an even coat of sealer (Fuji Bond
C: 004403004 or three bond 1105 (00440310) or equiva-
lent) to end of pinion housing.
3) Use the same number of shims as that used when
steering body was removed.
4) If steering body, valve housing or pinion and valve is
replaced with a new one, add two or three shims, install
valve on pinion housing and tighten with two bolts to 25±5
N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb). Then, measure clear-
ance between steering body and valve housing using a
thickness gauge. Remove shims so that the clearance is
zero.
B4M0670A
5) Extend rack“L”beyond pinion side of steering body.
L: 70.8 mm (2.787 in)
G4M0853
6) Apply grease to pinion gear teeth and ball bearing.
Insert valve into place.
7) Alternately and slowly tighten socket bolts.
NOTE:
Replace faulty parts before installing valve. Otherwise,
valve may not be installed properly.
Tightening torque:
25±5 N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
61
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0098
7. Pipe Assembly (Power Steering
System) [LHD model]
A: REMOVAL
1) Disconnect battery minus terminal.
G4M0099
2) Lift vehicle and remove jack-up plate.
3) Remove one pipe joint at the center of gearbox, and
connect vinyl hose to pipe and joint. Discharge fluid by
turning steering wheel fully clockwise and counterclock-
wise. Discharge fluid similarly from the other pipe.
CAUTION:
Improper removal and installation of parts often
causes fluid leak trouble. To prevent this, clean the
surrounding portions before disassembly and
reassembly, and pay special attention to keep dirt and
other foreign matter from mating surfaces.
G4M0162
4) Remove clamp E from pipes C and D.
62
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

G4M0101
5) Disconnect pipe C⋅D from pipe (on the gearbox side).
CAUTION:

When disconnecting pipe C⋅D, use two wrenches to
prevent deformities.

Be careful to keep pipe connections free from for-
eign matter.
B4M0556A
6) Remove bolt A.
Disconnect pipe C from oil pump. Disconnect pipe D from
oil tank.
CAUTION:

Do not allow fluid from the hose end to come into
contact with pulley belt.

To prevent foreign matter from entering the hose
and pipe, cover the open ends of them with a clean
cloth.
B: CHECK
Check all disassembled parts for wear, damage or other
abnormalities. Repair or replace faulty parts as required.
Part name Inspection Remedy
Pipe
O-ring fitting surface for
damage

Nut for damage

Pipe for damageReplace with new one.
Clamp

Clamps for weak
clamping forceReplace with new one.
Clamp E
Hose
Flared surface for
damage

Flare nut for damage

Outer surface for cracks

Outer surface for wear

Clip for damage

End coupling or adapter
for degradationReplace with new one.
63
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

B4M0556A
C: ASSEMBLY
1) Interconnect pipes C and D.
Tightening torque:
Joint nut
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
Visually check that hose between tank and pipe D is
free from bending or twisting.
2) Tighten bolt A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
G4M0165
3) Temporarily connect pipes C and D to pipes (on the
gearbox side).
64
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

B4M0557A
4) Temporarily install clamp E on pipes C and D.
CAUTION:
Ensure that the letter“8”on each clamp side are
diagonally opposite each other as shown in the figure.
5) Tighten clamp E firmly.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.20 kg-m, 5.4±1.4 ft-lb)
6) Tighten joint nut.
Tightening torque:
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
G4M0099
7) Connect pipes A and B to four pipe joints of gearbox.
Connect upper pipe B first, and lower pipe A second.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
8) Install jack-up plate.
9) Connect battery minus terminal.
10) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
65
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

G4M0167
11) Finally check clearance between pipes and/or hoses,
as shown above.
If clearance between cruise control pump and power steer-
ing hose is less than 10 mm (0.39 in), proceed as follows:
(1) Move clamped section
A(refer to figure above.)
down to a point where pipe is close to crossmember.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(2) Check that clearance between cruise control pump
and power steering hose is at least 10 mm (0.39 in). If
it is not, bend section
Bdown until a clearance of at
least 10 mm (0.39 in) is obtained.
66
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

G4M0098
8. Pipe Assembly (Power Steering
System) [RHD model]
A: REMOVAL
1) Disconnect battery negative terminal.
B4M0671A
2) Lift vehicle and remove jack-up plate.
3) Remove one pipe joint at the center of gearbox, and
connect vinyl hose to pipe and joint. Discharge fluid by
turning steering wheel fully clockwise and counterclock-
wise. Discharge fluid similarly from the other pipe.
CAUTION:
Improper removal and installation of parts often
causes fluid leak trouble. To prevent this, clean the
surrounding portions before disassembly and
reassembly, and pay special attention to keep dirt and
other foreign matter from mating surfaces.
B4M0672A
4) Remove clamp E from pipes C and D.
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4-3SERVICE PROCEDURE
8. Pipe Assembly (Power Steering System) [RHD model]