1999 SUBARU LEGACY Service Repair Manual

CAUTION:
Be careful not to damage housing and input
shaft, or to allow foreign matters to get inside
when removing dust seal.
C: INSPECTION
1) Clean all disassembled parts, and check for
wear, damage, or any other faults, then repair or
replace as necessary.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 ªService limitº.)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for dam-
age.
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 ªService limitº.)
(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 ªService limitº.)
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.
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[W3C0]4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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. Never vise gearbox by inserting alumi-
num plates, etc. between vise and gearbox.
ST 926200000 STAND
Sliding resistance of rack shaft:
Service limit
240.3 N (24.5 kg, 54.0 lb) or less
G4M0109
G4M0110
2. RACK SHAFT PLAY IN RADIAL
DIRECTION
Right-turn steering:
Service limit
0.15 mm (0.0059 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0111
Left-turn steering:
Service limit
Direction
0.3 mm (0.012 in) or less
Direction
0.15 mm (0.0059 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0887
3. INPUT SHAFT PLAY
In radial direction:
Service limit
0.18 mm (0.0071 in) or less
On condition
P: 98 N (10 kg, 22 lb)
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4-3[W3C1]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0113
In axial direction:
Service limit
0.1 mm (0.004 in) or less
On condition
P:20Ð49N(2Ð5kg,4Ð11lb)
G4M0114
4. TURNING RESISTANCE OF GEARBOX
Using ST, measure gearbox turning resistance.
ST 926230000 SPANNER
Service limit:
Straight-ahead position within 30 mm (1.18
in) from rack center
Less than 11.18 N (1.14 kg, 2.51 lb)
Maximum allowable resistance
12.7 N (1.3 kg, 2.9 lb)
G4M0115
D: ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No.
003608001)
1) Apply grease to teeth of rack so that grease
applied is about as high as teeth, and also apply a
thin film of grease to sliding portion of rack shaft.
CAUTION:
IWhen moving rack to stroke end without tie-
rod attached, prevent shocks from being
applied at the end.
IDo not apply grease to threaded portion at
end of rack shaft.
IMove rack shaft to stroke end two or three
times to squeeze grease which accumulates on
both ends. Remove grease to prevent it from
choking air passage hole.
2) Apply grease to sleeve insertion hole.
3) Apply grease to dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If mate-
rial having a sharp edge is used for applying
grease, oil seal at the inside might be damaged.
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).
G4M0116
Depth: A
2 mm (0.08 in)
G4M0117
19
[W3D0]4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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.
B4M1129A
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.
G4M0107
NOTE:
While tightening ball joint, hold rack with ST to
prevent it from revolving.7) Bend lock washer using a chisel.
CAUTION:
Be careful not to scratch rack when bending
lock washer.
G4M0120
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.
B4M1130A
(4) Tighten adjusting screw by two threads.
G4M0121
20
4-3[W3D0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

(5) Apply liquid packing to at least 1/3 of entire
perimeter of adjusting screw thread.
Liquid packing:
THREE BOND 1141
G4M0662
(6) Tighten adjusting screw to 15 N´m (1.5
kg-m, 11 ft-lb) and back off 26É.
(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:
IHold adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
IMake adjustment so that steering wheel can be
rotated fully from lock to lock without binding.
9) Check for service limit as per article of ªService
limitº.
Make replacement and
adjustment if necessary.
10) Install boot and mounting rubber to housing.
NOTE:
Apply grease through small hole in boot.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.
G4M0123
NOTE:
IBefore installing boot, be sure to apply grease to
the groove of tie-rod.
IInstall fitting portions of boots to the following
portions in both sides of assembled steering gear-
box.
(1) The groove on gearbox
(2) The groove on the rod
IMake sure that boot is installed without unusual
inflation or deflation.
12) Turn boot until it seats well on gearbox and
rubber mounting, then bend boot flange back.
G4M0124
21
[W3D0]4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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.
G4M0125
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.
G4M0126
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.
G4M0127
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
gearbox. 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)
(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)
G4M0101
E: INSTALLATION
1) Insert gearbox into crossmember, being careful
not to damage gearbox boot.
22
4-3[W3E0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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)
G4M0102
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 gear box, setting the bolt
hole in the cutout.
(3) Insert the bolt through the short yoke, pull
the joint and confirm that the bolt is on cutout of
the gearbox.
(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)
G4M0086
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
60É 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.
G4M0097
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. 4-3 [W9A0].>
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.
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[W3E0]4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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.
G4M0132
F: ADJUSTMENT
1) Adjust front toe.
Standard of front toe:
IN 3 Ð OUT 3 mm (IN 0.12 Ð OUT 0.12
in)
G4M0133
2) Adjust steering angle of wheels.
Steering angle:
Except OUTBACK model;
Inner wheel 37.6É
±1.5
Outer wheel 32.6É
±1.5
OUTBACK model;
Inner wheel 34.4É
±1.5
Outer wheel 30.2É
±1.5
3) If steering wheel spokes are not horizontal
when wheels are set in the straight ahead position,
and error is more than 5É on the periphery of steer-
ing wheel, correctly re-install the steering wheel.
B4M0133A
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.
G4M0135
24
4-3[W3F0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]