1999 SUBARU LEGACY replacement

4. Replacement of Front SFJ,
DOJ and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
5) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
6) Remove SFJ, DOJ and BJ boots from drive
shaft. or [W3B2].>
B: INSTALLATION
1) Install SFJ, DOJ and BJ boots to drive shaft.
or
2) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
3) Connect transverse link to housing.
4) Install stabilizer link.
5. Replacement of Rear DOJ
and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
3) Remove ABS sensor clamps and parking brake
cable bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove bolts which secure trailing link assem-
bly to rear housing.
7) Remove crossmember reinforcement lower
from crossmember (4 door model only).
8) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
CAUTION:
Be careful not to damage side bearing retainer.
Always use bolt as shown in figure, as support-
ing point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0995
36
4-2[W4A0]SERVICE PROCEDURE
4. Replacement of Front SFJ, DOJ and BJ Boots

9) Remove DOJ from rear differential using tire
lever. (2200 cc AT vehicles)
NOTE:
The side spline shaft circlip comes out together
with the shaft.
G3M0257
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the axle shaft
holder.
G3M0045
10) Remove DOJ and BJ boots from drive shaft.

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

2) Replace circlips from DOJ spline with new one.
(2200 cc AT vehicles only)3) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0549A
4) Insert DOJ spline end into bore of side oil seal,
and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0550A
5) Align DOJ and differential splines.
6) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
CAUTION:
Discard old self-locking nut. Replace with a
new one.
7) Connect rear housing assembly to trailing link
assembly, and tighten self-locking nut.
8) Connect rear housing assembly to lateral link
37
[W5B0]4-2SERVICE PROCEDURE
5. Replacement of Rear DOJ and BJ Boots

10. Installation of Wheel
Assembly to Vehicle
1) Attach the wheel to the hub by aligning the
wheel bolt hole with the hub bolt.
2) Temporarily attach the wheel nuts to the hub
bolts. (In the case of aluminum wheel, use
SUBARU genuine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the
wheel hub hole is aligned correctly to the guide
portion of hub.
4) Tighten the wheel nuts in a diagonal selection
to the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
CAUTION:
ITighten the wheel nuts in two or three steps
by gradually increasing the torque and working
diagonally, until the specified torque is
reached. For drum brake models, excess tight-
ening of wheel nuts may cause wheels to ªjud-
derº.
IDo not depress the wrench with a foot;
Always use both hands when tightening.
IMake sure the bolt, nut and the nut seating
surface of the wheel are free from oils.
5) If a wheel is removed for replacement or for
repair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
11. Tire Rotation
If tires are maintained at the same positions for a
long period of time, uneven wear results.
Therefore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or
damaged tires with new ones.
G4M0301
41
[W1100]4-2SERVICE PROCEDURE
11. Tire Rotation

10. Installation of Wheel
Assembly to Vehicle
1) Attach the wheel to the hub by aligning the
wheel bolt hole with the hub bolt.
2) Temporarily attach the wheel nuts to the hub
bolts. (In the case of aluminum wheel, use
SUBARU genuine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the
wheel hub hole is aligned correctly to the guide
portion of hub.
4) Tighten the wheel nuts in a diagonal selection
to the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
CAUTION:
ITighten the wheel nuts in two or three steps
by gradually increasing the torque and working
diagonally, until the specified torque is
reached. For drum brake models, excess tight-
ening of wheel nuts may cause wheels to ªjud-
derº.
IDo not depress the wrench with a foot;
Always use both hands when tightening.
IMake sure the bolt, nut and the nut seating
surface of the wheel are free from oils.
5) If a wheel is removed for replacement or for
repair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).
11. Tire Rotation
If tires are maintained at the same positions for a
long period of time, uneven wear results.
Therefore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or
damaged tires with new ones.
G4M0301
41
[W1100]4-2SERVICE PROCEDURE
11. Tire Rotation

(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]

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]

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]

6. Control Valve (Power Steering Gearbox) [RHD model]
A: CHECKING OIL LEAKING POINTS
B4M0668A
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
42
4-3[W6A0]SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]