SUBARU LEGACY 1999 Service Repair Manual

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]

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]

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. <Ref. to 4-3 [W6A2].> 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]

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. <Ref. to 4-3
[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]