SUBARU LEGACY 1995 Service Repair Manual

G4M0801
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
On condition
P: 20—49N(2—5 kg, 4—11 lb)
G4M0802
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 resistance:
Less than 20%
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:

When rack is fully moved to its stroke ends with tie-
rod removed, be careful not to bump rack ends.

Ensure 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.
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4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

G4M0803
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.

1Sleeve

2Seat

3Spring

4Adjusting screw

5Lock nut
G4M0804
5) Installation of tie-rod
(1) Tighten adjusting screw until it will no longer
tighten.
(2) 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)
G4M0805
(3) The left and right tie-rod differ as indicated in the
table below.
Right tie-rod
(pinion side)No air vent hole provided.Grooved.
(for identification)
Left tie-rod
(cylinder side)Air vent hole provided.Not grooved.
(for identification)
G4M0806
6) Using a chisel and hammer, bend lock washers (at two
places).
CAUTION:
Be careful not to scratch rack.
G4M0807
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.
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4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

G4M0662
(4) Turn adjusting screw so that the entire thread area
is coated with liquid packing.
Liquid packing:
THREE BOND 1102 or equivalent
NOTE:

Apply liquid packing of approximately 1.5 grams (0.053
oz) to adjusting screw thread area.

Also turn plug to ensure that its entire contact area is
coated with liquid packing.
G4M0808
(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 26°.
(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)
CAUTION:

Do not allow liquid packing to come in contact with
sleeve.

While 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:

Ensure that both ends of boot are properly situated
in grooves.

Ensure that boot is free from abnormal swelling or
dents.
G4M0790
9) Attach lock wire to boot large end, and twist it while
pulling it upward with a force of approximately 39±10 N
(4±1 kg, 9±2 lb).
ST 927590000 WRENCH
CAUTION:
Ensure that lock wire is not loose.
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4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

G4M0810
10) Then bend wire end along boot as shown.
G4M0812
11) Install clip using pliers.
CAUTION:
After installing clip, ensure that boot’s small end is
properly positioned in groove on tie-rod.
12) Install pipes A and B.
Tightening torque:
20±4 N⋅m (2.0±0.4 kg-m, 14.5±2.9 ft-lb)
G4M0132
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.
G4M0133
F: ADJUSTMENT
1) Adjust front toe.
Standard of front toe:
IN 3—OUT 3 mm (IN 0.12—OUT 0.12 in)
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4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

2) Adjust steering angle of wheels.
Standard of steering angle:
Inner wheel 37.6°±1.5°
Outer wheel 32.6°±1.5°
B4M0133A
3) If steering wheel spokes are not horizontal when wheels
are set in the straight ahead position, and error is more
than 5°on the periphery of steering wheel, correctly re-in-
stall the steering wheel.
G4M0135
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.
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4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

5. Control Valve (Power Steering
Gearbox) [LHD model]
NOTE:
This section focuses on the disassembly and reassembly
of control valve. For the inspection and adjustment and the
service procedures for associated parts, refer to“Steering
Gearbox”.
G4M0136
1Power cylinder

2Cylinder

3Rack piston

4Rack axle

5Input shaft
6Torsion bar

7Valve housing

8Valve body

9Control valve
10Pipe B

11Pipe A

12Pinion

13Pinion axle
A: CHECKING OIL LEAKING POINTS
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform check
step 5) in [W5A2] 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 necessary to thor-
oughly remove the oil from the suspected portion and turn
the steering wheel from lock to lock about 30 to 40 times
with engine running, then make comparison of the sus-
pected 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 com-
pleting repair work, clean these areas again.
40
4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

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 disassembly work, accidental
damage as well as inevitable 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 replacement
parts as much as possible.
1) Leakage from“a”
The oil seal is damaged. Replace valve assembly with a
new one.
2) Leakage from“b”
The torsion bar O-ring is damaged. Replace valve assem-
bly with a new one.
3) Leakage from“c”
The oil seal is damaged. Replace valve assembly with a
new one.
4) Leakage from“d”
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 steering 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“e”
The cylinder seal is damaged. Replace rack bush with a
new one.
7) Leakage from“f”
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 comparison of the
leaked portion between immediately after and several
hours after this operation.
CAUTION:

If leakage from“f”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.

If oil stops leaking from“f”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
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4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

G4M0137
B: DISASSEMBLY
1. VALVE ASSEMBLY
1) Loosen two bolts securing valve assembly.
G4M0138
2) Carefully draw out input shaft and remove valve assem-
bly.
G4M0139
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.
G4M0140
2. RACK ASSEMBLY
1) Slide mounting rubber to expose slit.
G4M0141
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
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4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

G4M0142
NOTE:
If ST is used, grind area (shown in figure) by 1 mm (0.04
in) in advance.
ST 926340000 WRENCH
G4M0143
3) Pull rack assembly from cylinder side, and draw out
rack bushing and rack stopper together with rack assem-
bly.
CAUTION:
Be careful not to contact rack to inner wall of cylinder
when drawing out. Any scratch on cylinder inner wall
will cause oil leakage.
4) Remove rack bushing and rack stopper from rack
assembly.
CAUTION:
Do not reuse removed rack bushing and circlip.
G4M0144
C: REPLACEMENT OF SEAL AND PACKING
1. VALVE HOUSING OIL SEAL

Removal
1) Pry off dust seal using screwdriver.
2) Remove snap ring using snap ring pliers.
G4M0145
3) Pry off oil seal using screwdriver.
CAUTION:
After removing, check inside surface of valve housing
for damage. If oil seal contacting surface is damaged,
replace valve housing with a new one.
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4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

G4M0146

Installation
1) Press-fit oil seal into valve housing using ST and press.
ST 927610000 INSTALLER
NOTE:
Before fitting, coat oil seal fully with ATF DEXRON II.
2) 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.
G4M0147
2. PINION AND VALVE ASSEMBLY

Removal
1) Remove snap ring using snap ring pliers.
CAUTION:

Do not reuse removed snap ring.

Be careful not to scratch pinion and valve assembly.
G4M0148
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.
3) Remove oil seal.
CAUTION:
Do not reuse removed oil seal.
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4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]