Subaru Legacy III (2000-2003 year). Manual - part 837

PS-36

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [LHD MODEL]

2) Loosen adjusting screw and remove spring and
sleeve.

CAUTION:
Replace spring and/or sleeve if damaged.

3) Remove two bolts securing valve assembly.

4) Carefully draw out input shaft and remove valve
assembly.

5) Slide dust cover out.

6) Draw out pinion and valve assembly from valve
housing, using pipe of I.D. 44 to 46 mm (1.73 to
1.81 in) and a press.

7) Using ST and press, remove oil seal and special
bearing from valve housing.
ST

34099FA120

INSTALLER & REMOVER 
SEAL

CAUTION:
• Do not apply a force to end surface of valve
housing.
• Do not reuse oil seal after removal.

8) Remove snap ring using snap ring pliers.

CAUTION:
• Do not reuse removed snap ring.
• Be careful not to scratch pinion and valve as-
sembly.

PS-00109

PS-00116

PS-00117

PS-00280

(1) Pipe

(1) Oil seal

(2) Special bearing

PS-00208

( 1 )

PS-00281

( 1 )

( 2 )

ST

PS-00154

PS-37

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [LHD MODEL]

9) Press out bearing together with backing washer
using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555
in) and press.

CAUTION:
Do not reuse removed bearing.

10) Remove oil seal.

CAUTION:
Do not reuse removed oil seal.

D: ASSEMBLY

1. RACK HOUSING ASSEMBLY

CAUTION:
Use only SUBARU genuine grease for gearbox.

Grease:

VALIANT GREASE M2
[Part No. 003608001, net 0.5 kg (1.1 lb)]

1) Force-fit oil seal using ST.
ST

34199AE050

INSTALLER

CAUTION:
Be careful not to damage or scratch cylinder in-
ner wall.

NOTE:
• Apply specified power steering fluid to oil seal.
• Pay special attention not to install oil seal in
wrong direction.
• Push oil seal until the stepped portion of A con-
tacts end face of B.

(1) Bearing

(2) Backing washer

(3) Oil seal

(4) Pipe

PS-00157

( 1 )

( 2 )

( 3 )

( 4 )

(1) Press

(2) Oil seal

PS-00158

A

B

ST

( 1 )

( 2 )

PS-38

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [LHD MODEL]

2) Fixing rack housing
Fix rack housing in vise using ST.
ST

926200000

STAND

CAUTION:
• When fixing rack housing in vise, be sure to
use this special tool. Do not fix rack housing in
vise using pad such as aluminum plates, etc.
• When using old rack housing, be sure to
clean and remove rust before assembling.
Check pinion housing bushing carefully.
3) Fit ST over toothed portion of rack assembly,
and check for binding or unsmooth insertion. If any
deformation is noted on flats at the end of rack,
shape by using file, and wash with cleaning fluid.
ST

926390001

COVER & REMOVER

4) Apply genuine grease to teeth of thoroughly
washed rack assembly, and fit ST over the toothed
portion.

CAUTION:
• Be careful not to block air passage hole with
grease. Remove excessive grease.
• After fitting cover, check air passage hole for
clogging. If clogged, open by removing grease
from the hole.
• Check rack shaft for damage.
• Apply specified power steering fluid to this
ST and surface of piston ring to prevent seal
from being damaged.
5) Insert rack assembly into rack housing from cyl-
inder side, and remove ST after it has passed com-
pletely through oil seal.

NOTE:
Before inserting rack assembly, apply a coat of
specified power steering fluid to surfaces of ST and
rack piston.
ST

926390001

COVER & REMOVER

6) Fit ST1 and ST2 over the end of rack, and install
rack bushing.
ST1

926400000

GUIDE

ST2

927660000

GUIDE

CAUTION:
• If burrs, or nicks are found on this guide and
rack shaft portion, remove by filing.
• Dip rack bushing in specified power steering
fluid before installing, and pay attention not to
damage O-ring and oil seal.

7) Insert rack stopper into cylinder tube until inter-
nal groove (on cylinder side) is aligned with exter-
nal groove (on rack stopper). Turn rack stopper
with ST so that rack stopper hole is seen through
cylinder slits.
8) Insert rack stopper into rack housing, and wrap
circlip using a sharp pointed pliers to secure rack
stopper in position.

CAUTION:
Be careful not to scratch rack while winding cir-
clip.

NOTE:
Rotate wrench another 90 to 180

°

 after the end of

circlip has been wrapped in.

9) Fit mounting rubber onto rack housing.

(1) Rack ASSY

PS-00161

( 1 )

ST

(1) Rack bushing ASSY

PS-00162

( 1 )

ST2

ST1

PS-00163

PS-39

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [LHD MODEL]

10) Apply genuine grease to pinion gear and bear-
ing of valve assembly.

11) Apply specified grease to dust cover.

12) Install dust cover on valve assembly.
13) Install gasket on valve assembly. Insert valve
assembly into place while facing rack teeth toward
pinion.

CAUTION:
Be sure to use a new gasket.

NOTE:
Do not allow packing to be caught when installing
valve assembly.

14) Tighten bolts alternately to secure valve as-
sembly.

 Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

CAUTION:
Be sure to alternately tighten bolts.

15) Apply grease to teeth of rack so that grease ap-
plied is about as high as teeth, and also apply a thin
film of grease to sliding portion of rack shaft.

CAUTION:
• When moving rack to stroke end without tie-
rod attached, prevent shocks from being ap-
plied at the end.
• Do not apply grease to threaded portion at
end of rack shaft.
• Move rack shaft to stroke end two (2) or three
(3) times to squeeze grease which accumulates
on both ends. Remove grease to prevent it from
choking air passage hole.
16) Apply grease to sleeve insertion hole.
17) Apply grease to dust seal insertion hole.

CAUTION:
Apply clean grease with clean hands. If material 
having a sharp edge is used for applying 
grease, oil seal at the inside might be damaged.
18) Apply grease to sliding surface of sleeve and
spring seat, then insert sleeve into pinion housing.
Fit spring into sleeve screw, pack grease inside of
screw, then install the screw.

PS-00165

PS-00282

PS-00117

(1) Adjusting screw

(2) Spring

(3) Sleeve

PS-00211

( 1 )

( 2 )

( 3 )