1997 SUBARU LEGACY boot

14. Replacement of Front FTJ and BJ
Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands (rigid
rocks), and remove front wheel cap and wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
G4M0279
5) Remove spring pin which secures transmission spindle
to FTJ.
CAUTION:
Use a new spring pin.
6) Remove FTJ and BJ boot from drive shaft.

B: INSTALLATION
1) Install FTJ and BJ boots to drive shaft.

G4M0279
2) Install FTJ on transmission spindle and drive spring pin
into place.
CAUTION:
Always use a new spring pin.
3) Connect transverse link to housing.
4) Install stabilizer link.
53
4-2SERVICE PROCEDURE
14. Replacement of Front FTJ and BJ Boots

1Clamp

2Adapter

3Hose bracket

4Pipe C

5Pipe D

6Clamp E

7Cap

8Strainer

9Seal washer

10Tank

11O-ring

12Oil pump

13Pulley

14Bracket

15Bush

16Belt cover

17Clamp plate

18Pipe F

19Pipe E

20Universal joint

21Dust seal

22C-ring

23Oil seal

24Valve housing

25Packing

26Seal ring

27Pinion and valve ASSY

28Oil seal

29Back-up washer

30Ball bearing

31Snap ring
32Lock nut

33Adjusting screw

34Spring

35Sleeve

36Adapter

37Clamp

38Cotter pin

39Castle nut

40Dust seal

41Clip

42Tie-rod end

43Small clip

44Boot

45Large clip

46Tie-rod

47Lock washer

48Pipe B

49Pipe A

50Housing ASSY

51Back-up washer

52Oil seal

53Piston ring

54Rack

55O-ring

56Rack bushing

57Oil seal

58Rack stopper

59Circlip

60Spacer

61Stay (2500 cc model only)

62Gasket
6
4-3COMPONENT PARTS
2. Power Steering System

1Clamp

2Adapter

3Hose bracket

4Pipe C

5Pipe D

6Clamp E

7Cap

8Strainer

9Seal washer

10Tank

11O-ring

12Oil pump

13Pulley

14Bracket

15Bush

16Belt cover

17Universal joint

18Dust cover

19Valve housing

20Y-packing

21Ball bearing

22Spacer

23Pinion

24Shim

25Adapter

26Clamp
27Castle nut

28Cotter pin

29Dust seal

30Clip

31Tie-rod end

32Clip

33Boot

34Wire

35Tie-rod

36Lock washer

37Holder

38Bush

39Y-packing

40Oil seal

41O-ring

42Rack

43Oil seal

44Back-up washer

45Housing ASSY

46Pipe A

47Pipe B

48Lock nut

49Adjusting screw

50Spring

51Sleeve

52Gasket
8
4-3COMPONENT PARTS
2. Power Steering System

3. Steering Gearbox (Power Steering
System) [LHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0131A
1Cotter pin

2Castle nut

3Dust cover

4Clip

5Tie-rod end

6Clip

7Boot

8Clip

9Spacer

10Tie-rod

11Lock washer

12Circlip

13Rack stopper

14Oil seal

15Rack bushing
16O-ring

17Rack

18Back-up washer

19Rack housing

20Adapter

21Clamp

22Lock nut

23Adjusting screw

24Spring

25Sleeve

26C-ring

27Ball bearing

28Valve

29Seal ring

30Packing
31Valve housing

32Dust seal

33Universal joint

34Spring washer
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 24±3 (2.4±0.3, 17.4±2.2)
T3: 25±5 (2.5±0.5, 18.1±3.6)
T4: 27.0±2.5
(2.75±0.25, 19.9±1.8)
T5: 39±10 (4.0±1.0, 29±7)
T6: 59±12 (6.0±1.2, 43±9)
T7: 78±10 (8.0±1.0, 58±7)
T8: 83±5 (8.5±0.5, 61.5±3.6)
15
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0101
9) Disconnect pipes C and D from pipe of gearbox.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect upper pipe D first, and lower pipe C second.
G4M0102
10) Remove clamp bolts securing gearbox to
crossmember, and remove gearbox.
B4M0132A
B: DISASSEMBLY
1) Disconnect four pipes from gearbox.
2) Secure gearbox removed from vehicle in vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox in a vice using the ST as shown.
Do not attempt to secure it without this ST.
3) Remove tie-rod end and lock nut from gearbox.
G4M0104
4) Remove small clip from boot using pliers, and move
boot to tie-rod end side.
G4M0105
5) Remove boot together with large clips.
17
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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.
19
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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]

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]