SUBARU LEGACY 1995 Service Repair Manual

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]

B4M0669A
2. VALVE ASSEMBLY
1) Remove traces of sealer, oil, rust, etc., from mating
surfaces of valve housing and steering body.
2) Position a shim in graded portion of steering body pin-
ion housing, and apply an even coat of sealer (Fuji Bond
C: 004403004 or three bond 1105 (00440310) or equiva-
lent) to end of pinion housing.
3) Use the same number of shims as that used when
steering body was removed.
4) If steering body, valve housing or pinion and valve is
replaced with a new one, add two or three shims, install
valve on pinion housing and tighten with two bolts to 25±5
N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb). Then, measure clear-
ance between steering body and valve housing using a
thickness gauge. Remove shims so that the clearance is
zero.
B4M0670A
5) Extend rack“L”beyond pinion side of steering body.
L: 70.8 mm (2.787 in)
G4M0853
6) Apply grease to pinion gear teeth and ball bearing.
Insert valve into place.
7) Alternately and slowly tighten socket bolts.
NOTE:
Replace faulty parts before installing valve. Otherwise,
valve may not be installed properly.
Tightening torque:
25±5 N⋅m (2.5±0.5 kg-m, 18.1±3.6 ft-lb)
61
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

G4M0098
7. Pipe Assembly (Power Steering
System) [LHD model]
A: REMOVAL
1) Disconnect battery minus terminal.
G4M0099
2) Lift vehicle and remove jack-up plate.
3) Remove one pipe joint at the center of gearbox, and
connect vinyl hose to pipe and joint. Discharge fluid by
turning steering wheel fully clockwise and counterclock-
wise. Discharge fluid similarly from the other pipe.
CAUTION:
Improper removal and installation of parts often
causes fluid leak trouble. To prevent this, clean the
surrounding portions before disassembly and
reassembly, and pay special attention to keep dirt and
other foreign matter from mating surfaces.
G4M0162
4) Remove clamp E from pipes C and D.
62
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

G4M0101
5) Disconnect pipe C⋅D from pipe (on the gearbox side).
CAUTION:

When disconnecting pipe C⋅D, use two wrenches to
prevent deformities.

Be careful to keep pipe connections free from for-
eign matter.
B4M0556A
6) Remove bolt A.
Disconnect pipe C from oil pump. Disconnect pipe D from
oil tank.
CAUTION:

Do not allow fluid from the hose end to come into
contact with pulley belt.

To prevent foreign matter from entering the hose
and pipe, cover the open ends of them with a clean
cloth.
B: CHECK
Check all disassembled parts for wear, damage or other
abnormalities. Repair or replace faulty parts as required.
Part name Inspection Remedy
Pipe
O-ring fitting surface for
damage

Nut for damage

Pipe for damageReplace with new one.
Clamp

Clamps for weak
clamping forceReplace with new one.
Clamp E
Hose
Flared surface for
damage

Flare nut for damage

Outer surface for cracks

Outer surface for wear

Clip for damage

End coupling or adapter
for degradationReplace with new one.
63
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]

B4M0556A
C: ASSEMBLY
1) Interconnect pipes C and D.
Tightening torque:
Joint nut
15±5 N⋅m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
CAUTION:
Visually check that hose between tank and pipe D is
free from bending or twisting.
2) Tighten bolt A.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
G4M0165
3) Temporarily connect pipes C and D to pipes (on the
gearbox side).
64
4-3SERVICE PROCEDURE
7. Pipe Assembly (Power Steering System) [LHD model]