Subaru Legacy (2005 year). Manual - part 847

PS-59

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD Model]

18) Apply liquid gasket to at least 1/3 of the entire
perimeter of adjusting screw thread.

Liquid gasket:

THREE BOND 1141 (Part No. 004403006)

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

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

Tightening torque:

9.8 N

⋅

m (1.0 kgf-m, 7.2 ft-lb)

21) After tightening the adjusting screw with the
specified tightening torque, loosen it by 30

°.

Tightening torque:

4.9 N

⋅

m (0.50 kgf-m, 3.6 ft-lb)

22) Remove the tie-rod.
23) Verify that play is within the specification. <Ref.
to PS-43, SERVICE LIMIT, INSPECTION, Steering
Gearbox [LHD Model].>

24) 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):

39 N

⋅

m (4.0 kgf-m, 28.9 ft-lb)

NOTE:
Hold the adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
25) Install the tie-rod into rack.

Tightening torque:

90 N

⋅

m (9.2 kgf-m, 66.4 ft-lb)

NOTE:
Check the mating face of rack and tie-rod for for-
eign material, dirt and etc.
26) Apply a coat of grease to the tie-rod groove,
and then install the boot to housing.

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

(1) Apply liquid gasket to at least 1/3 of entire 

perimeter

(1) Sleeve

(2) Spring

(3) Adjusting screw

PS-00092

PS-00167

(2)

(1)

(3)

PS-00094

PS-60

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD Model]

27) Caulk the boot so that the clearance of boot
band caulking portion becomes 2 mm (0.08 in) or
less.

NOTE:
Use a new boot band.

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

29) After installing, check that the boot end is posi-
tioned into groove on tie-rod.
30) If the tie-rod end has been removed, screw in
lock nut and tie-rod end to the screwed portion of
tie-rod, and tighten the lock nut temporarily in a po-
sition as shown in the figure.

Installed tie-rod length L:

31 mm (1.22 in)

31) 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.

32) Remove the gearbox from ST.
ST1

926200000

STAND

ST2

34199AG000 BOSS D

33) Install the pipe A and B to steering body and
control valve housing.

Tightening torque:

T1: 20 N

⋅

m (2.0 kgf-m, 14.5 ft-lb)

T2: 24 N

⋅

m (2.4 kgf-m, 17.4 ft-lb)

(A) Boot band

(B) 2 mm (0.08 in) or less

(1) Clip

PS-00499

(A)

(B)

PS-00053

(1) Pipe A

(2) Pipe B

PS-00097

L

PS-00098

B

A

PS-00500

T1

T2

T1

T2

(2)

(1)

PS-61

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD Model]

E: INSPECTION

1. BASIC 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 the inside of gearbox for water. If any water is found, carefully check the 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 serration

If the bend or damage is excessive, replace the entire 
gearbox.

2

Dust  seal

(1) Crack or damage
(2) Wear

If the outer wall slips, the lip is worn out or damage is 
found, replace it with a new one.

3

Rack & Pinion

Poor mating of rack with pinion

(1) Adjust the backlash properly. 
By measuring the turning torque of gearbox and sliding 
resistance of rack, check if rack & pinion engage uni-
formly 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 
the entire gearbox.

4

Gearbox unit

(1) Bend of rack shaft
(2) Bend of cylinder portion
(3) Crack or damage on cast iron 
portion

Replace the gearbox with a new one.

(4) Wear or damage on rack bush

If the free play of rack shaft in radial direction is out of the 
specified range, replace the gearbox with new one. (Refer 
to “Service limit”.)

(5) Wear on input shaft bearing

If the free play of rack shaft in radial and axial direction is 
out of the specified range, replace the gearbox with a 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-rod

Replace.

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

Pipe

(1) Damage to flared surface
(2) Damage to flare nut
(3) Damage to pipe

Replace.

PS-62

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD Model]

2. SERVICE LIMIT

Make a measurement as follows. If it exceeds the
specified service limit, adjust or replace.

NOTE:
When making a measurement, vise the gearbox
using ST. Never vise the gearbox by inserting alu-
minum plates, etc. between vise and gearbox.
ST1

926200000

STAND

ST2

34199AG000 BOSS D

Sliding resistance of rack shaft:

Service limit

314 N (32 kgf, 71 lbf) or less

Difference between right and left sliding resis-
tance:

20% or less

3. RACK SHAFT PLAY IN RADIAL DIREC-
TION

Right-turn steering:

Service limit

Direction  

0.4 mm (0.016 in) or less

Direction  

0.6 mm (0.024 in) or less

On condition

L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lbf)

Left-turn steering:

Service limit

Direction    

0.4 mm (0.016 in) or less

(1) Right-turn steering

(1) Left-turn steering

PS-00324

(1)

PS-00325

(1)

(1) Under the step

(2) Right-turn steering

(3) Measure point

(4) Right

(1) Under the step

(2) Left-turn steering

(3) Measure point

(4) Left

PS-00326

P

L

L

(1)

(2)

(3)

(4)

PS-00327

P

L

L

(1)

(2)

(3)

(4)