boot SUBARU LEGACY 1999 Service Service Manual

(4) Turn adjusting screw so that the entire
thread area is coated with liquid packing.
Liquid packing:
THREE BOND 1102 or equivalent
NOTE:
IApply liquid packing of approximately 1.5 grams
(0.053 oz) to adjusting screw thread area.
IAlso turn plug to ensure that its entire contact
area is coated with liquid packing.
G4M0662
(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 26É.
(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)
G4M0808
CAUTION:
IDo not allow liquid packing to come in con-
tact with sleeve.
IWhile 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:
IEnsure that both ends of boot are properly
situated in grooves.
IEnsure that boot is free from abnormal swell-
ing or dents.
9) Attach lock wire to boot large end, and twist it
while pulling it upward with a force of approxi-
mately 39±10N(4±1 kg, 9±2 lb).
ST 927590000 WRENCH
CAUTION:
Ensure that lock wire is not loose.
G4M0790
10) Then bend wire end along boot as shown.
G4M0810
11) Install clip using pliers.
CAUTION:
After installing clip, ensure that boot's small
end is properly positioned in groove on tie-rod.
G4M0812
12) Install pipes A and B.
Tightening torque:
20
±4 N´m (2.0±0.4 kg-m, 14.5±2.9 ft-lb)
33
[W4D0]4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

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.
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.
Standard of steering angle:
Inner wheel 37.6É
±1.5É
Outer wheel 32.6É
±1.5É
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 amount.
G4M0135
34
4-3[W4E0]SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

5. Control Valve (Power Steering Gearbox) [LHD model]
A: CHECKING OIL LEAKING POINTS
B4M1132A
(1) Power cylinder
(2) Cylinder
(3) Rack piston
(4) Rack axle
(5) Input shaft(6) Torsion bar
(7) Valve housing
(8) Valve body
(9) Control valve
(10) Pipe B(11) Pipe A
(12) Pinion
(13) Pinion axle
1. OIL LEAKING POINTS
1) If leak point is other than a, b, c, or d, perform
check step 5) in ªOIL LEAK CHECK PROCEDURE
AND REPLACEMENT PARTSº 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 nec-
essary to thoroughly remove the oil from the sus-
pected portion and turn the steering wheel from
lock to lock about 30 to 40 times with engine
running, then make comparison of the suspected
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 completing repair work, clean these
areas again.
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 disas-sembly work, accidental damage as well as inevi-
table 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 replace-
ment parts as much as possible.
1) Leakage from ªaº
The oil seal is damaged. Replace valve assembly
with a new one.
2) Leakage from ªbº
The torsion bar O-ring is damaged. Replace valve
assembly with a new one.
3) Leakage from ªcº
The oil seal is damaged. Replace valve assembly
with a new one.
4) Leakage from ªdº
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 steer-
ing 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.
35
[W5A2]4-3SERVICE PROCEDURE
5. Control Valve (Power Steering Gearbox) [LHD model]

boots toward tie-rod end side, respectively, with the
gearbox mounted to the vehicle, and remove oil
from the surrounding portions. Then, turn the steer-
ing 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 ªeº
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 compari-
son of the leaked portion between immediately
after and several hours after this operation.
CAUTION:
IIf leakage from ªeº 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.
IIf oil stops leaking from ªeº:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are dam-
aged during disassembly with new ones.
B: DISASSEMBLY
NOTE:
This section focuses on the disassembly and reas-
sembly of control valve. For the inspection and
adjustment and the service procedures for associ-
ated parts, refer to ªSteering Gearbox (Power
Steering System) [RHD model]º. [W400].>
1. VALVE ASSEMBLY
1) Slide dust cover out.
CAUTION:
IBe careful not to scratch housing or input
shaft during dust cover removal. Also do not
allow foreign matter to enter housing interior.
IReplace dust cover with a new one if its
inside bore or lips are worn or damaged.
G4M0817
2) Remove the two bolts securing valve housing.
G4M0818
3) Remove valve housing, pinion and valve as a
unit.
G4M0819
2. RACK ASSEMBLY
1) Remove holder using a 32 mm (1.26 in) wrench
or adjustable wrench.
CAUTION:
Discard old holder and replace with new one.
G4M0820
43
[W6B2]4-3SERVICE PROCEDURE
6. Control Valve (Power Steering Gearbox) [RHD model]

1. Front Disc Brake
A: EXCEPT 2500 cc MODEL
B4M1152C
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Lock pin (Yellow)(9) Support
(10) Pad clip
(11) Outer shim
(12) Inner shim
(13) Pad (Outside)
(14) Pad (Inside)
(15) Disc rotor
(16) Disc coverTightening 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)
T3:37±5 (3.8±0.5, 27.5±3.6)
T4:78±10 (8.0±1.0, 58±7)
6
4-4[C1A0]COMPONENT PARTS
1. Front Disc Brake

B: 2500 cc MODEL
B4M1151C
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Boot ring(9) Lock pin (Yellow)
(10) Support
(11) Pad clip
(12) Outer shim
(13) Inner shim
(14) Pad (Outside)
(15) Pad (Inside)
(16) Disc rotor(17) Disc 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)
T3:37±5 (3.8±0.5, 27.5±3.6)
T4:78±10 (8.0±1.0, 58±7)
7
[C1B0]4-4COMPONENT PARTS
1. Front Disc Brake

2. Rear Disc Brake
B4M0066B
(1) Lock pin
(2) Lock pin sleeve
(3) Lock pin boot
(4) Air bleeder screw
(5) Caliper body
(6) Guide pin
(7) Guide pin boot
(8) Piston seal
(9) Piston
(10) Piston boot
(11) Boot ring
(12) Support
(13) Shim
(14) Inner shim
(15) Inner pad(16) Pad clip
(17) Outer pad
(18) Outer shim
(19) Shoe hold-down pin
(20) Cover
(21) Back plate
(22) Retainer
(23) Spring washer
(24) Parking brake lever
(25) Parking brake shoe (Secondary)
(26) Parking brake shoe (Primary)
(27) Adjusting spring
(28) Strut
(29) Strut shoe spring
(30) Shoe guide plate(31) Secondary shoe return spring
(32) Primary shoe return spring
(33) Adjuster
(34) Shoe hold-down cup
(35) Shoe hold-down spring
(36) Disc rotor
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:20±4 (2.0±0.4, 14.5±2.9)
T3:26±5 (2.7±0.5, 19.5±3.6)
T4:52±6 (5.3±0.6, 38.3±4.3)
8
4-4[C200]COMPONENT PARTS
2. Rear Disc Brake

3. Rear Drum Brake
B4M1120A
(1) Air bleeder cap
(2) Air bleeder screw
(3) Boot
(4) Piston
(5) Cup
(6) Spring
(7) Wheel cylinder body
(8) Pin
(9) Plug
(10) Back plate(11) Upper shoe return spring
(12) Retainer
(13) Washer
(14) Parking brake lever
(15) Brake shoe (Trailing)
(16) Brake shoe (Leading)
(17) Shoe hold-down spring
(18) Cup
(19) Adjusting lever
(20) Adjuster(21) Lower shoe return spring
(22) Adjusting spring
(23) Drum
(24) Plug
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:10±2 (1.0±0.2, 7.2±1.4)
T3:52±6 (5.3±0.6, 38.3±4.3)
9
[C300]4-4COMPONENT PARTS
3. Rear Drum Brake

C: DISASSEMBLY
1. EXCEPT 2500 cc MODEL
B4M1152D
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Lock pin (Yellow)(9) Support
(10) Pad clip
(11) Outer shim
(12) Inner shim
(13) Pad (Outside)
(14) Pad (Inside)
(15) Disc rotor
(16) Disc coverTightening 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)
T3:37±5 (3.8±0.5, 27.5±3.6)
T4:78±10 (8.0±1.0, 58±7)
1) Clean mud and foreign particles from caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
20
4-4[W1C1]SERVICE PROCEDURE
1. Front Disc Brake

2) Gradually supply compressed air via caliper
body brake hose to force piston out.
CAUTION:
IPlace a wooden block as shown in Figure to
prevent damage to piston.
IDo not apply excessively high-pressure.
B4M1174A
3) Remove piston boot.
4) Remove piston seal from caliper body cylinder.
B4M1173A
5) Remove guide pin and boot from caliper body.
21
[W1C1]4-4SERVICE PROCEDURE
1. Front Disc Brake