boot SUBARU LEGACY 1999 Service Owner's Guide

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 con-
nector 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 Supplemental Restraint
System before performing the service opera-
tion. 3. Steering Gearbox (Power
Steering System) [LHD model]
A: REMOVAL
NOTE:
For disassembly and assembly of gearbox unit,
refer to section Control Valve (Power Steering
Gearbox) [LHD model]. and

B4M0131B
(1) Cotter pin
(2) Castle nut
(3) Dust cover
(4) Clip
(5) Tie-rod end
(6) Clip
(7) Boot
(8) Clip
(9) Spacer
(10) Tie-rod
(11) Lock washer
(12) Circlip
(13) Rack stopper
(14) Oil seal
(15) Rack bushing(16) O-ring
(17) Rack
(18) Back-up washer
(19) Rack housing
(20) Adapter
(21) Clamp
(22) Lock nut
(23) Adjusting screw
(24) Spring
(25) Sleeve
(26) C-ring
(27) Ball bearing
(28) Valve
(29) Seal ring
(30) Packing(31) Valve housing
(32) Dust seal
(33) Universal joint
(34) Spring 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)
14
4-3[W3A0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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 con-
nector 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 Supplemental Restraint
System before performing the service opera-
tion. 3. Steering Gearbox (Power
Steering System) [LHD model]
A: REMOVAL
NOTE:
For disassembly and assembly of gearbox unit,
refer to section Control Valve (Power Steering
Gearbox) [LHD model]. and

B4M0131B
(1) Cotter pin
(2) Castle nut
(3) Dust cover
(4) Clip
(5) Tie-rod end
(6) Clip
(7) Boot
(8) Clip
(9) Spacer
(10) Tie-rod
(11) Lock washer
(12) Circlip
(13) Rack stopper
(14) Oil seal
(15) Rack bushing(16) O-ring
(17) Rack
(18) Back-up washer
(19) Rack housing
(20) Adapter
(21) Clamp
(22) Lock nut
(23) Adjusting screw
(24) Spring
(25) Sleeve
(26) C-ring
(27) Ball bearing
(28) Valve
(29) Seal ring
(30) Packing(31) Valve housing
(32) Dust seal
(33) Universal joint
(34) Spring 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)
14
4-3[W3A0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

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.
B4M0132A
3) Remove tie-rod end and lock nut from gearbox.
4) Remove small clip from boot using pliers, and
move boot to tie-rod end side.
G4M0104
5) Remove boot together with large clips.
G4M0105
6) Straighten lock washer under ball joint.
CAUTION:
IBe extremely careful not to hit surface of
right hand rack; otherwise, oil leakage may
result.
ITie-rod lock washer must be replaced with a
new one whenever it is removed.
G4M0106
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
G4M0107
8) Loosen lock nut using ST, and remove adjust-
ing screw.
ST 926230000 SPANNER
G4M0108
9) Remove spring and sleeve.
10) Remove dust seal.
16
4-3[W3B0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

CAUTION:
Be careful not to damage housing and input
shaft, or to allow foreign matters to get inside
when removing dust seal.
C: INSPECTION
1) Clean all disassembled parts, and check for
wear, damage, or any other faults, then repair or
replace as necessary.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 ªService limitº.)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for dam-
age.
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 ªService limitº.)
(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 ªService limitº.)
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.
17
[W3C0]4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

(5) Apply liquid packing to at least 1/3 of entire
perimeter of adjusting screw thread.
Liquid packing:
THREE BOND 1141
G4M0662
(6) Tighten adjusting screw to 15 N´m (1.5
kg-m, 11 ft-lb) and back off 26É.
(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:
IHold adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
IMake adjustment so that steering wheel can be
rotated fully from lock to lock without binding.
9) Check for service limit as per article of ªService
limitº.
Make replacement and
adjustment if necessary.
10) Install boot and mounting rubber to housing.
NOTE:
Apply grease through small hole in boot.11) Fit clip (large) to boot, and then install boot to
gearbox while holding boot flange.
After installing boot, fold back boot flange to the
extent that large clip can not be seen.
G4M0123
NOTE:
IBefore installing boot, be sure to apply grease to
the groove of tie-rod.
IInstall fitting portions of boots to the following
portions in both sides of assembled steering gear-
box.
(1) The groove on gearbox
(2) The groove on the rod
IMake sure that boot is installed without unusual
inflation or deflation.
12) Turn boot until it seats well on gearbox and
rubber mounting, then bend boot flange back.
G4M0124
21
[W3D0]4-3SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

13) Fix boot end with clip (small).
CAUTION:
Use screwdriver with blunted tip to prevent
boot from damage, when installing.
NOTE:
After installing, check boot end is positioned into
groove on tie-rod.
G4M0125
14) If tie-rod end was removed, screw in lock nut
and tie-rod end to screwed portion of tie-rod, and
tighten lock nut temporarily in a position as shown
in figure.
Installed tie-rod length: L
15 mm (0.59 in)
NOTE:
Pay attention to difference between right and left
tie-rod ends.
G4M0126
15) Inspect gearbox as follows:
A) Holding tie-rod end, repeat lock to lock two or
three times as quickly as possible.
B) Holding tie-rod end, turn it slowly at a radius
one or two times as large as possible.
After all, make sure that boot is installed in the
specified position without deflation.
G4M0127
16) Remove gearbox from ST.
ST 926200000 STAND
17) Install four pipes on gearbox.
(1) Connect pipes A and B to four pipe joints of
gearbox. Connect upper pipe B first, and lower
pipe A.
Tightening torque:
13
±3 N´m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
(2) Connect pipes C and D to gearbox.
Connect lower pipe C first, and upper pipe D
second.
Tightening torque:
15
±5 N´m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
G4M0101
E: INSTALLATION
1) Insert gearbox into crossmember, being careful
not to damage gearbox boot.
22
4-3[W3E0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

15) After adjusting toe-in and steering angle,
tighten lock nut on tie-rod end.
Tightening torque:
83
±5 N´m (8.5±0.5 kg-m, 61.5±3.6 ft-lb)
CAUTION:
When adjusting toe-in, hold boot as shown to
prevent it from being rotated or twisted. If
twisted, straighten it.
G4M0132
F: ADJUSTMENT
1) Adjust front toe.
Standard of front toe:
IN 3 Ð OUT 3 mm (IN 0.12 Ð OUT 0.12
in)
G4M0133
2) Adjust steering angle of wheels.
Steering angle:
Except OUTBACK model;
Inner wheel 37.6É
±1.5
Outer wheel 32.6É
±1.5
OUTBACK model;
Inner wheel 34.4É
±1.5
Outer wheel 30.2É
±1.5
3) If steering wheel spokes are not horizontal
when wheels are set in the straight ahead position,
and error is more than 5É on the periphery of steer-
ing wheel, correctly re-install the steering wheel.
B4M0133A
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 turns.
G4M0135
24
4-3[W3F0]SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System) [LHD model]

4. Steering Gearbox (Power
Steering System) [RHD model]
A: REMOVAL
NOTE:
For disassembly and assembly of gearbox unit,
refer to section Control Valve (Power Steering
Gearbox) [RHD model]. and

B4M0666B
(1) Dust cover
(2) Valve housing
(3) Y-packing
(4) Ball-bearing
(5) Spacer
(6) Pinion
(7) Shim
(8) Dust seal(9) Clip
(10) Tie-rod end
(11) Clip
(12) Boot
(13) Wire
(14) Tie-rod RH
(15) Lock washer
(16) Sleeve(17) Spring
(18) Adjusting screw
(19) Lock nut
(20) Pipe A
(21) Pipe B
(22) Adapter
(23) Housing ASSY
(24) Back-up washer
25
[W4A0]4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

3) Pry off clip from outer end of boot, and slide
boot toward tie-rod end.
G4M0789
4) Using ST, remove lock wire from inner end of
boot, and remove boot.
ST 927590000 WRENCH
G4M0790
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.
G4M0791
6) Using ST, loosen lock nut.
ST 926230000 SPANNER
G4M0792
7) Tighten adjusting screw until it no longer tight-
ens.
G4M0793
8) Using a wrench [32 mm (1.26 in) width across
flats] or adjustable wrench, remove tie-rod.
CAUTION:
ICheck ball joint for free play, and tie-rod for
bends. Replace if necessary.
ICheck dust seals used with tie-rod end ball
joint for damage or deterioration. Replace if
necessary.
G4M0794
9) Loosen adjusting screw and remove spring and
sleeve.
CAUTION:
Replace spring and/or sleeve if damaged.
28
4-3[W4B0]SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

10) Disconnect pipes A and B from steering body
and control valve housing.
CAUTION:
Replace pipes and/or flare nuts if damaged.
G4M0795
C: INSPECTION
1) Clean all disassembled parts, and check for
wear, damage, or any other faults, then repair or
replace as necessary.
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.

(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for dam-
age.
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.
(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.

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.
29
[W4C0]4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]