Subaru Legacy (2005 year). Manual - part 841

PS-35

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

11) Using a press, press-fit until the groove of ST
are aligned to the end surface of holder.

12) Secure the gearbox in a vise using ST.
ST1

926200000

STAND

ST2

34199AG000 BOSS D

13) Tighten the holder.

Tightening torque:

70 N

⋅

m (7.1 kgf-m, 51.6 ft-lb)

14) Using the ST, caulk so that the diameter of
punch hole is 2 — 2.5 mm (0.08 — 0.10 in) and is
aligned to the position of 2 mm from gearbox cylin-
der end surface.
ST

34099FA060

PUNCH HOLDER

15) Put a vinyl tape around the spline portion and
apply genuine grease to the dust cover and install
to valve assembly.

CAUTION:
Be sure to install the dust cover to groove of 
shaft.

16) Apply genuine grease to the pinion gear and
bearing of valve assembly.

(1) Groove

(2) Holder

(1) Clamp

(1) Holder

PS-00522

ST

(1)

(2)

PS-00492

(1)

ST1

ST2

PS-00512

(1)

(1) 2 mm (0.08 in)

(2) Diameter: 2 

—

 2.5 mm (0.08 

—

 0.10 in)

(3) End of cylinder

(4) Holder

(1) Dust cover

(2) Groove

PS-00523

(1)

(2)

(4)

(3)

PS-00534

(1)

(2)

 PS-00165

PS-36

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

17) Install a new gasket on valve assembly. Insert
the valve assembly into place while facing the rack
teeth toward pinion.

18) Tighten the bolts alternately to secure the valve
assembly.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

CAUTION:
Be sure to alternately tighten the bolts.
19) Temporarily install the tie-rod to the rack end,
and then operate the rack from lock to lock for two
or three times to make it fit in. Remove the grease
blocking air vent hole.

CAUTION:
If operating the rack from lock to lock without 
installing tie-rod, it may damage the oil seal. Al-
ways install the tie-rods LH and RH.
20) Apply liquid gasket around the center of adjust-
ing screw threads.

Liquid gasket:

THREE BOND 1141 (Part No. 004403006)

21) Apply a coat of grease to the sliding surface of
sleeve and seating surface of spring, and then in-
sert the sleeve into steering body.
Charge the adjusting screw with grease, and then
insert the spring into adjusting screw and install on
steering body.

22) Tighten the adjusting screw to specified torque,
then loosen it.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

23) After tightening the adjusting screw with the
specified tightening torque, loosen it by 20

°.

Tightening torque:

3.9 N

⋅

m (0.4 kgf-m, 2.9 ft-lb)

24) Remove the tie-rod.
25) Verify that play is within the specification. <Ref.
to PS-43, SERVICE LIMIT, INSPECTION, Steering
Gearbox [LHD Model].>
26) Install the lock nut. While holding the adjusting
screw with a wrench, tighten the lock nut using ST.
ST

926230000

SPANNER

Tightening torque (Lock nut):

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

NOTE:
Hold the adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
27) Extend the rack approx. 40 mm (1.57 in) from
steering body.
28) Install the tie-rod and new lock washer into
rack.

Tightening torque:

78 N

⋅

m (8.0 kgf-m, 57.9 ft-lb)

(1) Sleeve

(2) Spring

(3) Adjusting screw

PS-00117

PS-00167

(2)

(1)

(3)

(1) Lock washer

(2) Approx. 40 mm (1.57 in)

PS-00439

(2)

(1)

PS-37

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

29) Bend the lock washer and caulk it.

CAUTION:
Be careful not to scratch the rack when caulk-
ing lock washer.

30) Apply a coat of grease to the tie-rod groove,
and then install the boot to housing.

CAUTION:
Right side boot has groove for identification, be 
sure to install the right and left of boot.

NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.

31) Install a new boot band. Using band clamp pli-
ers, caulk it so that the clearance of caulking por-
tion becomes 2 mm (0.079 in) or less.

32) Fix the boot end with clip (small).

(1) Lock washer

(1) Right side boot

(2) Groove for identification

PS-00093

PS-00524

(2)

(1)

(A) Boot band

(B) 2 mm (0.079 in) or less

(1) Clip

PS-00194

PS-00499

(A)

(B)

PS-00661

(1)

PS-38

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

33) After installing, check the boot end is installed
to the groove of tie-rod.
34) If the tie-rod end has been removed, screw in
the lock nut and tie-rod end to the screwed portion
of tie-rod, and tighten the lock nut temporarily in a
position as shown in the figure.

Installed tie-rod length L:

31 mm (1.22 in)

35) Inspect the 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 the boot is installed in the
specified position without deflation.

36) Remove the gearbox from ST.
ST1

926200000

STAND

ST2

34199AG000 BOSS D

37) Install the four pipes on gearbox.

(1) Connect the pipes A and B to the four pipe
joints of gearbox.

Tightening torque:

13 N

⋅

m (1.3 kgf-m, 9.6 ft-lb)

(2) Connect the pipes C and D to gearbox.

Tightening torque:

Pipe C: 15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

Pipe D: 25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

2. CONTROL VALVE ASSEMBLY

Steering grease:

VALIANT GREASE M2 (Part No. 003608001)

1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to
the inner wall of valve housing.

3) To avoid scratching oil seal, apply a coat of
grease to the contact surface of installer and oil
seal.
4) Verify the direction of oil seal. Install the oil seal
to installer and position it to valve housing.

PS-00097

L

PS-00098

B

A

(1) Pipe C

(2) Pipe D

(1) Apply fluid.

PS-00525

(1)

(2)

PS-00169

(1)