boot SUBARU LEGACY 1996 Service Service Manual

1Dust cover

2Valve housing

3Y-packing

4Ball-bearing

5Spacer

6Pinion

7Shim

8Dust seal

9Clip

10Tie-rod end

11Clip

12Boot

13Wire

14Tie-rod RH

15Lock washer

16Sleeve
17Spring

18Adjusting screw

19Lock nut

20Pipe A

21Pipe B

22Adapter

23Housing ASSY

24Back-up washer

25Oil seal

26Rack

27O-ring

28Oil seal

29Y-packing

30Bush

31Holder

32Tie-rod LH
29
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

9) Remove flare nuts from control valve of gearbox
assembly, and disconnect upper and lower hoses B and A.
CAUTION:

Always disconnect hoses B and A in that order.

Be careful not to damage the hoses during removal.
10) Remove bolts securing gearbox to crossmember, and
detach gearbox.
G4M0788
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 assembly in a vice using the ST as
shown. Do not attempt to secure it without this ST.
G4M0789
3) Pry off clip from outer end of boot, and slide boot toward
tie-rod end.
G4M0790
4) Using ST, remove lock wire from inner end of boot, and
remove boot.
ST 927590000 WRENCH
G4M0791
5) Extend rack approximately 40 mm (1.57 in) out. Unlock
lock wire at lock washer on each side of tie-rod end using
a standard screwdriver.
CAUTION:
Be careful not to scratch rack surface as oil leaks may
result.
31
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD 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.
33
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.
37
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)
38
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD 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.
41
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”
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“e”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“e”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are damaged
during disassembly with new ones.
50
4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

8. CLEARANCE TABLE (RHD MODEL)
CAUTION:
This table lists various clearances that must be cor-
rectly adjusted to ensure normal vehicle driving with-
out interfering noise, or any other faults.
LocationMinimum
allowance
mm (in)LocationMinimum
allowance
mm (in)

1Crossmember—Pipe5 (0.20)5Stabilizer—Pipe5 (0.20)

2DOJ—Shaft or joint14 (0.55)6Exhaust pipe—Pipe15 (0.59)

3DOJ—Valve housing11 (0.43)7Exhaust pipe—Gearbox boot15 (0.59)

4Pipe—Pipe
2 (0.08)
8Side frame—Hose A and B15 (0.59)
Pipe—Crossmember9Pipe portion of hose A—Pipe portion of hose B1.5
(0.059)
B4M0676A
98
4-3DIAGNOSTICS
1. Power Steering

1. Front Disc Brake
1. EXCEPT 2500 cc AND OUTBACK (STEP ROOF)
MODEL
B4M0065A
1Air bleeder screw

2Guide pin

3Guide pin boot

4Piston

5Piston seal

6Piston boot

7Lock pin boot

8Lock pin sleeve

9Caliper body
10Lock pin

11Housing

12Support

13Pad clip

14Outer shim

15Outer pad

16Inner pad

17Inner shim

18Shim
19Disc rotor

20Disc cover
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 39±5 (4±0.5, 28.9±3.6)
T4: 78±10 (8.0±1.0, 58±7)
9
4-4COMPONENT PARTS
1. Front Disc Brake

2. 2500 cc AND OUTBACK (STEP ROOF) MODEL
G4M0990
1Lock pin

2Lock pin sleeve

3Lock pin boot

4Caliper body

5Air bleeder screw

6Guide pin

7Guide pin boot

8Piston seal

9Piston
10Piston boot

11Boot ring

12Support

13Pad clip

14Outer shim

15Pad (Outside)

16Pad (Inside)

17Inner shim

18Shim
19Disc rotor

20Disc cover
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 36±5 (3.7±0.5, 26.8±3.6)
T4: 49±5 (5.0±0.5, 36.2±3.6)
T5: 78±10 (8.0±1.0, 58±7)
10
4-4COMPONENT PARTS
1. Front Disc Brake