SUBARU LEGACY 1996 Service Repair Manual

G5M0328
6) Align center of roll connector. (with airbag model)

CAUTION:
Ensure that front wheels are set in straight-forward
direction.
7) Set steering wheel to neutral and install it onto steering
shaft.
Tightening torque:
34±5 N⋅m (3.5±0.5 kg-m, 25.3±3.6 ft-lb)
Column cover-to-steering wheel clearance:
2 — 4 mm (0.08 — 0.16 in)
CAUTION:
Insert roll connector guide pin into guide hole on lower
end of surface of steering wheel to prevent damage.
Draw out airbag system connector, horn connector
and cruise control connectors from guide hole of
steering wheel lower end. (with airbag model)
8) Install airbag module to steering wheel. (with airbag
model)
WARNING:
Always refer to 5-5 [W3B1] before performing the ser-
vice operation.
14
4-3SERVICE PROCEDURE
2. Tilt Steering Column

3. Steering Gearbox (Power Steering
System) [LHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0131A
1Cotter pin

2Castle nut

3Dust cover

4Clip

5Tie-rod end

6Clip

7Boot

8Clip

9Spacer

10Tie-rod

11Lock washer

12Circlip

13Rack stopper

14Oil seal

15Rack bushing
16O-ring

17Rack

18Back-up washer

19Rack housing

20Adapter

21Clamp

22Lock nut

23Adjusting screw

24Spring

25Sleeve

26C-ring

27Ball bearing

28Valve

29Seal ring

30Packing
31Valve housing

32Dust seal

33Universal joint

34Spring washer
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 24±3 (2.4±0.3, 17.4±2.2)
T3: 25±5 (2.5±0.5, 18.1±3.6)
T4: 27.0±2.5
(2.75±0.25, 19.9±1.8)
T5: 39±10 (4.0±1.0, 29±7)
T6: 59±12 (6.0±1.2, 43±9)
T7: 78±10 (8.0±1.0, 58±7)
T8: 83±5 (8.5±0.5, 61.5±3.6)
15
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

A: REMOVAL
1) Disconnect battery minus terminal.
2) Loosen front wheel nut.
3) Lift vehicle and remove front wheels.
4) Remove front exhaust pipe assembly.
WARNING:
Be careful, exhaust pipe is hot.
G4M0097
5) Using a puller, remove tie-rod end from knuckle arm
after pulling off cotter pin and removing castle nut.
G4M0098
6) Remove jack-up plate and front stabilizer.
G4M0099
7) 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.
G4M0086
8) Remove lower side bolt of universal joint, then remove
upper side bolt and lift the joint upward.
NOTE:
Place a mark on the joint and mating serration so that they
can be re-installed at the original position.
16
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0101
9) Disconnect pipes C and D from pipe of gearbox.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect upper pipe D first, and lower pipe C second.
G4M0102
10) Remove clamp bolts securing gearbox to
crossmember, and remove gearbox.
B4M0132A
B: DISASSEMBLY
1) Disconnect four pipes from gearbox.
2) Secure gearbox removed from vehicle in vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox in a vice using the ST as shown.
Do not attempt to secure it without this ST.
3) Remove tie-rod end and lock nut from gearbox.
G4M0104
4) Remove small clip from boot using pliers, and move
boot to tie-rod end side.
G4M0105
5) Remove boot together with large clips.
17
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0106
6) Straighten lock washer under ball joint.
CAUTION:

Be extremely careful not to hit surface of right hand
rack; otherwise, oil leakage may result.

Tie-rod lock washer must be replaced with a new
one whenever it is removed.
G4M0107
7) Loosen ball joint using ST and spanner and remove
tie-rod from rack.
NOTE:
When loosening ball joint, securely fix the rack using ST.
ST 925700000 WRENCH
G4M0108
8) Loosen lock nut using ST, and remove adjusting screw.
ST 926230000 SPANNER
9) Remove spring and sleeve.
10) Remove dust seal.
CAUTION:
Be careful not to damage housing and input shaft, or
to allow foreign matters to get inside when removing
dust seal.
18
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

C: INSPECTION
1) Clean all disassembled parts, and check for wear,
damage, or any other faults, then repair or replace as nec-
essary.
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.
(Refer to“Service limit”.)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for
damage.
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. (Refer to“Service
limit”.)
(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.
(Refer to“Service limit”.)
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.
19
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0109
G4M0110
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 aluminum plates, etc.
between vise and gearbox.
ST 926200000 STAND
Sliding resistance of rack shaft:
Service limit
240.3 N (24.5 kg, 54.0 lb) or less
G4M0111
2. RACK SHAFT PLAY IN RADIAL DIRECTION
Right-turn steering:
Service limit
0.15 mm (0.0059 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0887
Left-turn steering:
Service limit
Direction
0.3 mm (0.012 in) or less
Direction
0.15 mm (0.0059 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0113
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)
20
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0114
In axial direction:
Service limit
0.1 mm (0.004 in) or less
On condition
P: 20—49N (2—5 kg, 4—11 lb)
G4M0115
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
12.7 N (1.3 kg, 2.9 lb)
D: ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No. 003608001)
1) Apply grease to teeth of rack so that grease applied is
about as high as teeth, and also apply a thin film of grease
to sliding portion of rack shaft.
CAUTION:

When moving rack to stroke end without tie-rod
attached, prevent shocks from being applied at the
end.

Do not apply grease to threaded portion at end of
rack shaft.

Move rack shaft to stroke end two or three times to
squeeze grease which accumulates on both ends.
Remove grease to prevent it from choking air passage
hole.
2) Apply grease to sleeve insertion hole.
3) Apply grease to dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If material hav-
ing a sharp edge is used for applying grease, oil seal
at the inside might be damaged.
21
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0116
4) Press-fit dust seal into gearbox housing while tapping it
via a spanner or the like so that stepping between gearbox
and dust seal is normally 2 mm (0.08 in).
G4M0117
Depth: A
2 mm (0.08 in)
G4M0118
5) Apply grease to sliding surface of sleeve and spring
seat, then insert sleeve into pinion housing. Fit spring into
sleeve screw, pack grease inside of screw, then install the
screw.

1Sleeve

2Spring

3Adjusting screw
G4M0107
6) Fit new lock washer on screwed portion of rack end.
Aligning cut portion of rack and nail of washer, screw in and
tighten ball joint by using ST and spanner.
ST 925700000 WRENCH
Tightening torque (Ball joint):
78±10 N⋅m (8.0±1.0 kg-m, 58±7 ft-lb)
CAUTION:
Pay attention to prevent rack surface on the right side
from being damaged by a tool or the like, otherwise oil
leakage might be caused.
NOTE:
While tightening ball joint, hold rack with ST to prevent it
from revolving.
22
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

G4M0120
7) Bend lock washer using a chisel.
CAUTION:
Be careful not to scratch rack when bending lock
washer.
G4M0122
8) Rack and pinion backlash adjustment
(1) Loosen adjusting screw.
(2) Rotate input shaft so that rack is in the straight
ahead direction.
(3) Apply grease to sleeve.

1Sleeve

2Spring

3Lock nut

4Adjusting screw
G4M0121
(4) Tighten adjusting screw by two threads.
G4M0662
(5) Apply liquid packing to at least 1/3 of entire perim-
eter of adjusting screw thread.
Liquid packing:
THREE BOND 1141
(6) Tighten adjusting screw to 15 N⋅m (1.5 kg-m, 11
ft-lb) and back off 26°.
(7) Install lock nut. While holding adjusting screw with
a wrench, tighten lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
39±10 N⋅m (4.0±1.0 kg-m, 29±7 ft-lb)
NOTE:

Hold adjusting screw with a wrench to prevent it from
turning while tightening lock nut.
23
4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]