1999 SUBARU LEGACY tow bar

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]

5) Fit ST1 and ST2 over the end of rack, and
install rack bushing.
ST1 926400000 GUIDE
ST2 927660000 GUIDE
CAUTION:
IIf burrs, or nicks are found on this guide and
rack shaft portion, remove by filing.
IDip rack bushing in specified power steering
fluid before installing, and pay attention not to
damage O-ring and oil seal.
G4M0156
6) Insert rack stopper into cylinder tube until inter-
nal groove (on cylinder side) is aligned with exter-
nal groove (on rack stopper). Turn rack stopper
with ST so that rack stopper hole is seen through
cylinder slits.
7) Insert rack stopper into rack housing, and wrap
circlip using ST to secure rack stopper in position.
ST 926340001 WRENCH
CAUTION:
Be careful not to scratch rack while winding
circlip.
NOTE:
Rotate wrench another 90 to 180É after the end of
circlip has been wrapped in.
G4M0157
8) Fit mounting rubber onto rack housing.
2. VALVE ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No.
003608001)
1) Apply genuine grease to pinion gear and bear-
ing of valve assembly.
G4M0158
2) Install packing on valve assembly. Insert valve
assembly into place while facing rack teeth toward
pinion.
CAUTION:
Be sure to use a new packing.
NOTE:
Do not allow packing to be caught when installing
valve assembly.
B4M0135
3) Tighten bolts alternately to secure valve assem-
bly.
Tightening torque:
25
±5 N´m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
CAUTION:
Be sure to alternately tighten bolts.
41
[W5D2]4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

(3) Using ST, press-fit shaft assembly into front
body and mount snap ring.
ST 340099AA020 INSTALLER
NOTE:
Turn snap ring to ensure that it fits right into the
groove.
G4M0185
3) Cartridge assembly
(1) Apply specified power steering fluid to
O-rings and fit them into front casing.
(2) Install side plate to front casing.
CAUTION:
Use care not to let side plate gall.
G4M0186
(3) Mount rotor onto shaft.
(4) Install 10 vanes into rotor with their nose
radius facing toward cam ring.
(5) Install cam ring to front casing, securing
with knock pins.
CAUTION:
Do not use hammer to fit knock pins in posi-
tion.
G4M0187
4) Rear cover
(1) Mount seal washer on front casing.
(2) With knock pin positions aligned, install rear
cover.
Tightening torque:
16
±2 N´m (1.6±0.2 kg-m, 11.6±1.4 ft-lb)
CAUTION:
Loosely tighten bolts in the sequence (1), (2),
(3), and (4) shown in figure. Then, tighten in the
same sequence.
B4M1139A
5) Spool Valve
CAUTION:
IUse care to prevent damage to O-ring at
installation.
IWhen tightening connector, ensure that
O-ring does not protrude or get caught.
(1) Install spring into front casing. Then, with
spool valve dipped in specified hydraulic oil,
install it into the front casing.
G4M0189
(2) Using a 5-mm dia. round bar, ensure that
valve moves smoothly.
(3) Set O-ring, with grease applied to it, onto
connector and secure connector to front casing.
Tightening torque:
74
±5 N´m (7.5±0.5 kg-m, 54.2±3.6 ft-lb)
6) Check
(1) When reassembly procedures have been
completed, turn shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions
are evident, disassemble again and check for
foreign matter trapped on sliding surfaces and
65
[W8E0]4-3SERVICE PROCEDURE
8. Oil Pump (Power Steering System)

24. Crossbar
A: REMOVAL
1) Loosen and remove TORX bolt T30 from the
top of each crossbar end support.
2) Rotate lower clamp on the bottom of each end
support downward approximately 90É.
B5M0576A
3) Remove crossbar.
B: INSTALLATION
1. FRONT CROSSBAR
NOTE:
Front crossbar has ªMAXIMUM LOAD 100LBS.
EVENLY DISTRIBUTEDº label on LH side.
1) Rotate lower clamp on the bottom of each end
support downward approximately 90É.
2) With the front direction arrow label on the top
right side of the crossbar pointing toward the front
of the vehicle, carefully place the crossbar across
the top of the vehicle so that the crossbar end
supports rest on the top of the roof rails approxi-
mately 127 mm (5 in) rearward from the joint
between the front roof rail support and the roof rail.
Length:
A: 127 mm (5 in)
B5M0577A
3) Rotate the lower clamp up to the bottom of the
roof rail and loose assemble the TORX bolt T30,
through the top of the end support and into the
threaded insert in the lower clamp on each end of
the crossbar.NOTE:
It may be necessary to squeeze the lower clamp
and the end support together to compress the pads
and gain a better alignment of the pieces while
trying to start the screw. Be careful not to cross
thread the screw in the insert.
4) Tighten TORX bolt T30.
Tightening torque:
3.7
±0.3 N´m (0.38±0.03 kg-m, 2.75±0.22
ft-lb)
B5M0578A
2. REAR CROSSBAR
NOTE:
Rear crossbar does not have the ªMAXIMUM
LOAD 100LBS. EVENLY DISTRIBUTEDº label.
1) Rotate lower clamp on the bottom of each end
support downward approximately 90É.
2) With the front direction arrow label on the top
right side of the crossbar pointing toward the front
of the vehicle, carefully place the crossbar across
the top of the vehicle so that the crossbar end
supports rest on the top of the roof rails approxi-
mately 127 mm (5 in) forward from the joint
between the rear roof rail support and the roof rail.
Length:
B: 127 mm (5 in)
B5M0579A
3) Rotate the lower clamp up to the bottom of the
roof rail and loose assemble the TORX bolt T30,
through the top of the end support and into the
threaded insert in the lower clamp on each end of
the crossbar.
65
[W24B2]5-1SERVICE PROCEDURE
24. Crossbar