1999 SUBARU LEGACY Service Repair Manual

(4) Turn adjusting screw so that the entire
thread area is coated with liquid packing.
Liquid packing:
THREE BOND 1102 or equivalent
NOTE:
IApply liquid packing of approximately 1.5 grams
(0.053 oz) to adjusting screw thread area.
IAlso turn plug to ensure that its entire contact
area is coated with liquid packing.
G4M0662
(5) Tighten adjusting plug to 5 N´m (0.5 kg-m,
3.6 ft-lb) and loosen, then tighten to 5 N´m (0.5
kg-m, 3.6 ft-lb) and loosen, and finally tighten to
5 N´m (0.5 kg-m, 3.6 ft-lb) and loosen 26É.
(6) While holding adjusting plug using a closed
wrench, tighten lock nut using ST.
ST 926300000 SPANNER
Tightening torque:
39
±10 N´m (4±1 kg-m, 29±7 ft-lb)
G4M0808
CAUTION:
IDo not allow liquid packing to come in con-
tact with sleeve.
IWhile rotating input shaft to fully move rack
shaft to the left and right, ensure that rack
moves smoothly without binding, and that
rotating torque is constant.
8) Installation of boot
(1) Apply a coat of grease to inner wall of boot
small end.
(2) Position boot large end in rubber mount
groove and gearbox, and small end in groove of
tie-rod.CAUTION:
IEnsure that both ends of boot are properly
situated in grooves.
IEnsure that boot is free from abnormal swell-
ing or dents.
9) Attach lock wire to boot large end, and twist it
while pulling it upward with a force of approxi-
mately 39±10N(4±1 kg, 9±2 lb).
ST 927590000 WRENCH
CAUTION:
Ensure that lock wire is not loose.
G4M0790
10) Then bend wire end along boot as shown.
G4M0810
11) Install clip using pliers.
CAUTION:
After installing clip, ensure that boot's small
end is properly positioned in groove on tie-rod.
G4M0812
12) Install pipes A and B.
Tightening torque:
20
±4 N´m (2.0±0.4 kg-m, 14.5±2.9 ft-lb)
33
[W4D0]4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

E: INSTALLATION
Installation is in the reverse order of removal.
Do the following:
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.
Standard of steering angle:
Inner wheel 37.6É
±1.5É
Outer wheel 32.6É
±1.5É
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 amount.
G4M0135
34
4-3[W4E0]SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

5. Control Valve (Power Steering Gearbox) [LHD model]
A: CHECKING OIL LEAKING POINTS
B4M1132A
(1) Power cylinder
(2) Cylinder
(3) Rack piston
(4) Rack axle
(5) Input shaft(6) Torsion bar
(7) Valve housing
(8) Valve body
(9) Control valve
(10) Pipe B(11) Pipe A
(12) Pinion
(13) Pinion axle
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform
check step 5) in ªOIL LEAK CHECK PROCEDURE
AND REPLACEMENT PARTSº 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 nec-
essary to thoroughly remove the oil from the sus-
pected portion and turn the steering wheel from
lock to lock about 30 to 40 times with engine
running, then make comparison of the suspected
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 completing repair work, clean these
areas again.
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 disas-sembly work, accidental damage as well as inevi-
table 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 replace-
ment parts as much as possible.
1) Leakage from ªaº
The oil seal is damaged. Replace valve assembly
with a new one.
2) Leakage from ªbº
The torsion bar O-ring is damaged. Replace valve
assembly with a new one.
3) Leakage from ªcº
The oil seal is damaged. Replace valve assembly
with a new one.
4) Leakage from ªdº
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 steer-
ing 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.
35
[W5A2]4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

6) Leakage from ªeº
The cylinder seal is damaged. Replace rack bush
with a new one.
7) Leakage from ªfº
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 compari-
son of the leaked portion between immediately
after and several hours after this operation.
CAUTION:
IIf leakage from ªfº 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.
IIf oil stops leaking from ªfº:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are dam-
aged during disassembly with new ones.
B: DISASSEMBLY
NOTE:
This section focuses on the disassembly and reas-
sembly of control valve. For the inspection and
adjustment and the service procedures for associ-
ated parts, refer to ªSteering Gearbox (Power
Steering System) [LHD model]º.

1. VALVE ASSEMBLY
1) Loosen two bolts securing valve assembly.
G4M0137
2) Carefully draw out input shaft and remove valve
assembly.
G4M0138
3) Draw out pinion and valve assembly from valve
housing, as necessary, using pipe of I.D. 44 to 46
mm (1.73 to 1.81 in) and a press.
G4M0139
2. RACK ASSEMBLY
1) Slide mounting rubber to expose slit.
G4M0140
36
4-3[W5B0]SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

2) Rotate rack stopper in the direction of arrow
using ST until the end of circlip comes out of
stopper, then rotate it in the opposite direction, and
pull out circlip.
ST 926340001 WRENCH
G4M0141
NOTE:
If ST is used, grind area (shown in figure) by 1 mm
(0.04 in) in advance.
ST 926340000 WRENCH
G4M0142
3) Pull rack assembly from cylinder side, and draw
out rack bushing and rack stopper together with
rack assembly.
CAUTION:
Be careful not to contact rack to inner wall of
cylinder when drawing out. Any scratch on cyl-
inder inner wall will cause oil leakage.
G4M0143
4) Remove rack bushing and rack stopper from
rack assembly.
CAUTION:
Do not reuse removed rack bushing and circlip.
C: REPLACEMENT OF SEAL AND
PACKING
1. VALVE HOUSING OIL SEAL
1) Pry off dust seal using screwdriver.
G4M0144
2) Remove snap ring using snap ring pliers.
37
[W5C1]4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

3) Pry off oil seal using screwdriver.
CAUTION:
After removing, check inside surface of valve
housing for damage. If oil seal contacting sur-
face is damaged, replace valve housing with a
new one.
G4M0145
4) Press-fit oil seal into valve housing using ST
and press.
ST 927610000 INSTALLER
NOTE:
Before fitting, coat oil seal fully with specified
power steering fluid.
G4M0146
5) Fit snap ring in snap ring groove using snap
ring pliers.
CAUTION:
Be careful not to scratch oil seal with snap ring
pliers.
NOTE:
Rotate snap ring to check for proper installation.
2. PINION AND VALVE ASSEMBLY
1) Remove snap ring using snap ring pliers.
CAUTION:
IDo not reuse removed snap ring.
IBe careful not to scratch pinion and valve
assembly.
G4M0147
2) Press out bearing together with backing washer
using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555
in) and press.
CAUTION:
Do not reuse removed bearing.
G4M0148
3) Remove oil seal.
CAUTION:
Do not reuse removed oil seal.
4) Fit pinion and valve assembly into valve hous-
ing.
38
4-3[W5C2]SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

NOTE:
Apply specified power steering fluid to outer diam-
eter surface of input shaft and outer surface of
valve body seal ring, and pay special attention not
to damage seal when inserting pinion and valve
assembly.
5) Secure valve assembly to ST1 and ST2.
ST1 926370000 INSTALLER A
ST2 927630000 STAND BASE
ST3 926360000 INSTALLER A
ST4 927620000 INSTALLER B
G4M0149
6) Put ST3 over pinion, and insert oil seal, then
force-fit oil seal into housing using ST4.
NOTE:
IApply specified power steering fluid to oil seal
and ST3, being careful not to damage oil seal lip.
IPush oil seal until ST3 contacts housing end
face.
7) Remove ST3, and fit backing washer.8) Force-fit ball bearing using ST3.
ST1 926370000 INSTALLER A
ST2 927630000 STAND BASE
ST3 927640000 INSTALLER B
NOTE:
Be careful not to tilt ball bearing during installation.
G4M0150
9) Install snap ring using snap ring pliers.
NOTE:
Rotate snap ring to check for proper installation.
3. RACK HOUSING OIL SEAL AND BACK-
UP WASHER
1) Insert a round rod [26 Ð 27 mm (1.02 Ð 1.06
in) dia.] from pinion housing side and remove oil
seal and back-up washer by hammering the rod.
NOTE:
IDiscard removed oil seal and back-up washer.
IApply the unchamfered end of remover to
back-up washer.
G4M0151
39
[W5C3]4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

2) Force-fit oil seal and back-up washer using ST.
ST 927650000 INSTALLER
CAUTION:
Be careful not to damage or scratch cylinder
inner wall.
NOTE:
IApply specified power steering fluid to oil seal.
IPay special attention not to install back-up
washer and oil seal in wrong direction.
IPush oil seal until the stepped portion of A con-
tacts end face of B.
G4M0152
D: ASSEMBLY
1. RACK ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No.
003608001)
1) Fixing rack housing
Fix rack housing in vice using ST.
ST 926200000 STAND
CAUTION:
IWhen fixing rack housing in vice, be sure to
use this special tool. Do not fix rack housing in
vice using pad such as aluminum plates, etc.
IWhen using old rack housing, be sure to
clean and remove rust before assembling.
Check pinion housing bushing carefully.
B4M0134A
2) Fit ST over toothed portion of rack assembly,
and check for binding or unsmooth insertion. If any
deformation is noted on flats at the end of rack,
shape by using file, and wash with cleaning fluid.
3) Apply genuine grease to teeth of thoroughly
washed rack assembly, and fit ST over the toothed
portion.
ST 926390001 COVER & REMOVER
CAUTION:
IBe careful not to block air passage with
grease. Remove excessive grease.
IAfter fitting cover, check air passage hole for
clogging. If clogged, open by removing grease
from the hole.
ICheck rack shaft for damage.
IApply specified power steering fluid to this
ST and surface of piston ring to prevent seal
from being damaged.
G4M0154
4) Insert rack assembly into rack housing from cyl-
inder side, and remove ST after it has passed com-
pletely through oil seal.
ST 926390001 COVER & REMOVER
NOTE:
Before inserting rack assembly, apply a coat of
specified power steering fluid to surfaces of ST and
rack piston.
G4M0155
40
4-3[W5D1]SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]