gearbox SUBARU LEGACY 1995 Service Service Manual

G4M0817
B: DISASSEMBLY
1. VALVE ASSEMBLY
1) Slide dust cover out.
CAUTION:

Be careful not to scratch housing or input shaft dur-
ing dust cover removal. Also do not allow foreign mat-
ter to enter housing interior.

Replace dust cover with a new one if its inside bore
or lips are worn or damaged.
G4M0818
2) Remove the two bolts securing valve housing.
G4M0819
3) Remove valve housing, pinion and valve as a unit.
G4M0820
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.
51
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0821
2) Install ST on valve side of rack and press outer side oil
seal out.
ST 34099FA030 INSTALLER & REMOVER
CAUTION:

Block pipe connection of steering body to prevent
fluid from flowing out.

Do not allow rack to come in contact with inner wall
of cylinder. Otherwise, cylinder wall may be scratched,
resulting in oil leaks.

Remove holder and rack as a unit.

Check rack and steering body for bends or cracks
and replace as required.

Discard oil seal after removal and replace with new
ones.
G4M0822
3) Insert ST from valve side and press back-up ring and oil
seal out.
CAUTION:
Discard back-up ring and oil seal after removal and
replace with new ones.
ST 927580000 REMOVER
52
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0823
4) Using ST1 and ST2, repair cylinder’s clinched sections.
ST1 34099FA080 PUNCH
ST2 34099FA070 BASE
G4M0889
5) If cylinder edge is deformed in a convex shape, repair
using an oil stone.
G4M0824
C: REPLACEMENT OF SEAL AND PACKING
1. VALVE HOUSING OIL SEAL

Removal
1) After removing dust cover, extract pinion and valve from
valve housing.
CAUTION:

If pinion and valve is difficult to remove, use a press.

Discard Y-packing after removal and replace with a
new one.

Check rotor for bends and serrations for damage
and replace as required.
53
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0825
2) Using ST and press, remove dust seal, back-up washer,
Y-packing and ball bearing from valve housing.
CAUTION:

Use the“A”end of remover.

Do not apply a force to end surface of valve hous-
ing.

Do not reuse Y-packing after removal.
ST 34099FA000 INSTALLER & REMOVER
G4M0836

Installation
Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
1) Apply a coat of grease to inner wall of valve housing,
Y-packing and outer perimeter of dust seal.
G4M0838
2) Using ST and press, install Y-packing in valve housing.
(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.
ST 34099FA000 INSTALLER & REMOVER
G4M0839
3) Attach ST2 to ST1, and press ball bearing into place
using a press.
NOTE:

To facilitate installation, attach ball bearing to remover
and position in valve housing before pressing it into place.

Use the“B”end of remover.
ST1 34099FA000 INSTALLER & REMOVER
ST2 34099FA050 SPACER
G4M0840
4) Charge Y-packing with specified steering grease.
54
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0841
5) Apply a coat of specified steering grease to ST surface,
and install ST onto end of input shaft. Insert pinion and
valve until“A”of oil seal contacts“B”of valve housing. The
ST is used to prevent scratching Y-packing.
ST 34099FA020 GUIDE
G4M0842
6) 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.
G4M0843
7) Apply a coat of grease to sealing lips of dust cover, and
insert dust cover until it contacts staged portion of input
shaft.
8) 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.
G4M0826
2. PINION AND VALVE ASSEMBLY

Removal
1) Remove snap ring securing valve sleeve to pinion and
valve, and remove valve sleeve.
CAUTION:
Be careful not to scratch pinion and valve when remov-
ing snap ring.
G4M0827
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.
55
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0828

Installation
1) Wash and clean pinion & valve and valve housing.
2) Attach ST to pinion, and apply grease to outer perimeter
of the cover and mating surface of oil seal.
ST 926270000 COVER
G4M0829
3) Apply a coat of grease to spacer and sealing lips of oil
seal, and install spacer and oil seal.
CAUTION:

Face chamfered side of spacer toward oil seal.

Face oil seal in correct direction.
G4M0830
4) Install ST to input shaft, and apply a coat of grease to
the cover surface. Install O-ring and seal ring.
CAUTION:
Do not expand O-ring and seal ring more than neces-
sary.
ST 926450000 COVER
G4M0831
5) Apply a coat of grease to inner wall of ST, and secure
seal ring assembled in step 4) as shown. Leave seal ring
unattended for approximately 10 minutes until it settles
down.
ST 926280000 FORMER
G4M0832
6) While aligning valve sleeve pin with groove on pinion,
secure with snap ring.
CAUTION:

Be careful not to damage inner wall of valve sleeve
and contact surface of pinion.

Before assembling valve sleeve and pinion, clean in
kerosene and dry with compressed air.
56
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0833
3. RACK PISTON SEAL RING AND O-RING

Removal
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 seal-
ing effect, resulting in faulty piston operation.
G4M0834

Installation
1) Wash clean rack piston.
2) Install O-ring and seal ring in groove on rack piston.
CAUTION:

Do not expand O-ring and seal ring more than nec-
essary.

To facilitate installation of seal ring, first position
one half of entire seal ring in groove. Then slowly posi-
tion the second half using a spatula, as shown.
G4M0835
3) 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.
CAUTION:
Be careful not to scratch rack, piston and seal ring
during installation.
ST 927600000 FORMER
57
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0844
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:

Use a ST to support steering body.

Ensure 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.
G4M0845
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.
G4M0846
3) Install back-up ring from gear side of rack.
G4M0890
4) Install ST on rack and equally apply a thin coat of
grease to rack and ST, then install oil seal.
CAUTION:
Be careful not to scratch oil seal lips with piston’s
knurl section.
ST 926250000 GUIDE
58
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0891
5) Apply a coat of grease to grooves in rack, sliding sur-
face 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.
CAUTION:

Be sure to apply grease so that it covers the entire
surface of rack gear teeth.

Do not allow grease to block air vent hole on rack.
ST 34099FA010 GUIDE (Oil seal)
G4M0892
6) Slowly press inner side oil seal until distance between
ST and end of rack is 65 mm (2.56 in).
CAUTION:
Ensure ST’s inner wall is free of scratches. Otherwise,
it may damage oil seal during installation.
ST 34099FA010 GUIDE (Oil seal)
G4M0893
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)
G4M0820
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)
59
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0850
9) Attach ST to rack cylinder. Using a press, install
back-up ring and oil seal.
NOTE:
Press ST until its groove is aligned with end of holder.
ST 34099FA030 INSTALLER & REMOVER
G4M0967
10) Using ST, clinch steering body cylinder at a point less
than 3 mm (0.12 in) from holder.
CAUTION:
Be careful not to deform holder.
ST 34099FA060 PUNCH HOLDER
60
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]