SUBARU LEGACY 1999 Service Repair Manual

10) Disconnect pipes A and B from steering body
and control valve housing.
CAUTION:
Replace pipes and/or flare nuts if damaged.
G4M0795
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.
<Ref. to 4-3 [W4C1].>
(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. <Ref. to 4-3 [W4C1].>
(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.
<Ref. to 4-3 [W4C1].>
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.
29
[W4C0]4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD 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
304 N (31 kg, 68 lb) or less
Difference between left and right sliding
resistance
Less than 20%
G4M0796
G4M0797
2. RACK SHAFT PLAY IN RADIAL
DIRECTION
Right-turn steering:
Service limit
Less than 0.4 mm (0.016 in) (direction
)
Less than 0.6 mm (0.024 in) (direction
)
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0798
Left-turn steering:
Service limit
Less than 0.4 mm (0.016 in)
(direction
and)
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0799
30
4-3[W4C1]SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

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)
G4M0800
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
On condition
P:20Ð49N(2Ð5kg,4Ð11lb)
G4M0801
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
15.79 N (1.61 kg, 3.55 lb) or less
Difference between left and right sliding resis-
tance:
Less than 20%
G4M0802
D: ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No.
003608001)
1) Clean all parts and tools before reassembling.
2) Move rack shaft fully to the left and right two or
three times to lubricate shaft ends with grease.
Remove excess grease, being careful not to block
air vent hole.
CAUTION:
IWhen rack is fully moved to its stroke ends
with tie-rod removed, be careful not to bump
rack ends.
IEnsure that screw located at end of rack
shaft is free from grease.
3) Apply grease to bore wall which accommodates
sleeve.
CAUTION:
Ensure that hands are clean when applying
grease.
31
[W4D0]4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

4) Apply a coat of grease to sliding surface of
sleeve and seating surface of spring, and insert
sleeve into steering body. Charge adjusting screw
with grease, insert spring into adjusting screw and
install on steering body.
B4M1131A
(1) Sleeve
(2) Seat
(3) Spring
(4) Adjusting screw
(5) Lock nut
5) Installation of tie-rod
(1) Tighten adjusting screw until it will no longer
tighten.
(2) The left and right tie-rod differ as indicated
in the table.
Right tie-rod
(pinion side)No air vent hole pro-
vided.Grooved.
(for identifica-
tion)
Left tie-rod
(cylinder side)Air vent hole provided.Not grooved.
(for identifica-
tion)
G4M0805
(3) Install lock washers and tighten left and
right tie-rods into rack ends.
On condition
L: Approximately 40 mm (1.57 in)
Tightening torque:
78
±10 N´m (8.0±1.0 kg-m, 58±7 ft-lb)
G4M0804
6) Using a chisel and hammer, bend lock washers
(at two places).
CAUTION:
Be careful not to scratch rack.
G4M0806
7) Rack and pinion backlash adjustment
(1) Loosen adjusting screw three to four turns.
(2) Rotate input shaft so that rack is in the
straight ahead direction. [Ensure that distance
between rack end and stopper is 70.8 mm
(2.787 in).]
(3) Tighten adjusting screw by two threads.
G4M0807
32
4-3[W4D0]SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

(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. <Ref. to 4-3 [W5A2].> 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.
<Ref. to 4-3 [W300].>
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]