1999 SUBARU LEGACY gearbox

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.
6) Leakage from ªeº
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 ªeº 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 ªeº:
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) [RHD model]º. [W400].>
1. VALVE ASSEMBLY
1) Slide dust cover out.
CAUTION:
IBe careful not to scratch housing or input
shaft during dust cover removal. Also do not
allow foreign matter to enter housing interior.
IReplace dust cover with a new one if its
inside bore or lips are worn or damaged.
G4M0817
2) Remove the two bolts securing valve housing.
G4M0818
3) Remove valve housing, pinion and valve as a
unit.
G4M0819
2. RACK ASSEMBLY
1) Remove holder using a 32 mm (1.26 in) wrench
or adjustable wrench.
CAUTION:
Discard old holder and replace with new one.
G4M0820
43
[W6B2]4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

2) Install ST on valve side of rack and press outer
side oil seal out.
ST 34099FA030 INSTALLER & REMOVER
CAUTION:
IBlock pipe connection of steering body to
prevent fluid from flowing out.
IDo not allow rack to come in contact with
inner wall of cylinder. Otherwise, cylinder wall
may be scratched, resulting in oil leaks.
IRemove holder and rack as a unit.
ICheck rack and steering body for bends or
cracks and replace as required.
IDiscard oil seal after removal and replace
with new ones.
G4M0821
3) Insert ST from valve side and press back-up
ring and oil seal out.
ST 927580000 REMOVER
CAUTION:
Discard back-up ring and oil seal after removal
and replace with new ones.
G4M0822
4) Using ST1 and ST2, repair cylinder's clinched
sections.
ST1 34099FA080 PUNCH
ST2 34099FA070 BASE
G4M0823
44
4-3[W6B2]SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

5) If cylinder edge is deformed in a convex shape,
repair using an oil stone.
G4M0889
C: REPLACEMENT OF SEAL AND
PACKING
1. VALVE HOUSING OIL SEAL
Specified steering grease:
VALIANT GREASE M2 (Part No.
003608001)
1) After removing dust cover, extract pinion and
valve from valve housing.
CAUTION:
IIf pinion and valve is difficult to remove, use
a press.
IDiscard Y-packing after removal and replace
with a new one.
ICheck rotor for bends and serrations for
damage and replace as required.
G4M0824
2) Using ST and press, remove dust seal, back-up
washer, Y-packing and ball bearing from valve
housing.
ST 34099FA000 INSTALLER & REMOVER
CAUTION:
IUse the ªAº end of remover.
IDo not apply a force to end surface of valve
housing.
IDo not reuse Y-packing after removal.
G4M0825
3) Apply a coat of grease to inner wall of valve
housing, Y-packing and outer perimeter of dust
seal.
G4M0836
45
[W6C1]4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

4) Using ST and press, install Y-packing in valve
housing.
ST 34099FA000 INSTALLER & REMOVER
(1) Face Y-packing in the direction shown in
figure when installing.
(2) To avoid scratching Y-packing, apply a coat
of grease to contact surface of installer and
Y-packing.
(3) To facilitate installation, attach Y-packing to
installer and position in valve housing before
pressing into place.
G4M0838
5) Attach ST2 to ST1, and press ball bearing into
place using a press.
ST1 34099FA000 INSTALLER & REMOVER
ST2 34099FA050 SPACER
NOTE:
ITo facilitate installation, attach ball bearing to
remover and position in valve housing before
pressing it into place.
IUse the ªBº end of remover.
G4M0839
6) Charge Y-packing with specified steering
grease.
G4M0840
7) Apply a coat of specified steering grease to ST
surface, and install ST onto end of input shaft.
Insert pinion and valve until ªAº of oil seal contacts
ªBº of valve housing. The ST is used to prevent
scratching Y-packing.
ST 34099FA020 GUIDE
G4M0841
8) While supporting pinion and valve, push end of
pinion until bearing contacts brazed end of valve
housing.
CAUTION:
Do not allow spacer to extend beyond brazed
end. Otherwise, pinion cannot be inserted
properly.
G4M0842
46
4-3[W6C1]SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

9) Apply a coat of grease to sealing lips of dust
cover, and insert dust cover until it contacts staged
portion of input shaft.
G4M0843
10) Adjust sealing lip-to-housing end clearance to
0 to 0.5 mm (0 to 0.020 in). If sealing lip is too close
to housing end, steering wheel will not return
smoothly; if it is too far from housing end, dust or
dirt will enter the clearance.
NOTE:
Ensure that pinion and valve is properly positioned
in valve housing before adjustment.
2. PINION AND VALVE ASSEMBLY
Specified steering grease:
VALIANT GREASE M2 (Part No.
003608001)
1) Remove snap ring securing valve sleeve to pin-
ion and valve, and remove valve sleeve.
CAUTION:
Be careful not to scratch pinion and valve when
removing snap ring.
G4M0826
2) Remove oil seal and spacer.
3) Using a long rod, remove seal ring and O-ring
from pinion.
CAUTION:
Be careful not to scratch outer surface and seal
ring groove of input shaft. If scratched, sealing
effect will be lost, resulting in a malfunctioning
valve.
G4M0827
4) Wash and clean pinion & valve and valve hous-
ing.
5) Attach ST to pinion, and apply grease to outer
perimeter of the cover and mating surface of oil
seal.
ST 926270000 COVER
G4M0828
6) Apply a coat of grease to spacer and sealing
lips of oil seal, and install spacer and oil seal.
CAUTION:
IFace chamfered side of spacer toward oil
seal.
IFace oil seal in correct direction.
G4M0829
47
[W6C2]4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

7) Install ST to input shaft, and apply a coat of
grease to the cover surface. Install O-ring and seal
ring.
ST 926450000 COVER
CAUTION:
Do not expand O-ring and seal ring more than
necessary.
G4M0830
8) Apply a coat of grease to inner wall of ST, and
secure seal ring assembled in former step as
shown. Leave seal ring unattended for approxi-
mately 10 minutes until it settles down.
ST 926280000 FORMER
G4M0831
9) While aligning valve sleeve pin with groove on
pinion, secure with snap ring.
CAUTION:
IBe careful not to damage inner wall of valve
sleeve and contact surface of pinion.
IBefore assembling valve sleeve and pinion,
clean in kerosene and dry with compressed air.
G4M0832
3. RACK PISTON SEAL RING AND
O-RING
Specified steering grease:
VALIANT GREASE M2 (Part No.
003608001)
1) Using a sharp-edged, long rod, remove seal
ring and O-ring from rack piston.
CAUTION:
Be careful not to scratch outer surface of rack
piston and seal ring groove. A scratch may
reduce the sealing effect, resulting in faulty
piston operation.
G4M0833
2) Wash clean rack piston.
3) Install O-ring and seal ring in groove on rack
piston.
CAUTION:
IDo not expand O-ring and seal ring more
than necessary.
ITo facilitate installation of seal ring, first
position one half of entire seal ring in groove.
Then slowly position the second half using a
spatula, as shown.
G4M0834
48
4-3[W6C3]SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

4) Apply a coat of grease to inner surface of ST
and insert rack piston into it. Leave ST at least 10
minutes until seal ring settles down in place.
ST 927600000 FORMER
CAUTION:
Be careful not to scratch rack, piston and seal
ring during installation.
G4M0835
D: ASSEMBLY
1. RACK ASSEMBLY
Specified steering grease:
VALIANT GREASE M2 (Part No.
003608001)
1) Attach steering body to ST as shown. Apply a
coat of grease to needle bearing.
ST 926200000 STAND
CAUTION:
IUse a ST to support steering body.
IEnsure that needle bearing is free from
defects. If it is faulty, replace steering body
with a new one.
NOTE:
If steering body is removed from vehicle, be sure
to remove rust and clean.
G4M0844
2) Using ST´B and ST´C, attach oil seal to ST´A.
Insert ST´A into rack from gear side. Remove oil
seal from ST´A when it approaches piston and
remove STs from rack.
ST 927490000 INSTALLER; A´B´C
NOTE:
Face oil seal in the direction shown in figure.
G4M0845
3) Install back-up ring from gear side of rack.
G4M0846
4) Install ST on rack and equally apply a thin coat
of grease to rack and ST, then install oil seal.
ST 926250000 GUIDE
CAUTION:
Be careful not to scratch oil seal lips with pis-
ton's knurl section.
G4M0890
49
[W6D1]4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

5) Apply a coat of grease to grooves in rack, slid-
ing surface of sleeve and sealing surface of piston.
Install ST on the end of steering body cylinder.
Then insert rack into steering body from cylinder
side.
ST 34099FA010 GUIDE (Oil seal)
CAUTION:
IBe sure to apply grease so that it covers the
entire surface of rack gear teeth.
IDo not allow grease to block air vent hole on
rack.
G4M0891
6) Slowly press inner side oil seal until distance
between ST and end of rack is 65 mm (2.56 in).
ST 34099FA010 GUIDE (Oil seal)
CAUTION:
Ensure ST's inner wall is free of scratches.
Otherwise, it may damage oil seal during instal-
lation.
G4M0892
7) Pass ST2 and pipe through rack and press
outer side oil seal until ST1 is in contact with ST2.
ST1 34099FA010 GUIDE (Oil seal)
ST2 34099FA040 INSTALLER (Oil seal)
G4M0893
8) Install holder from cylinder side of steering
body.
Tightening torque:
64
±5 N´m (6.5±0.5 kg-m, 47.0±3.6 ft-lb)
G4M0820
50
4-3[W6D1]SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]