Subaru Legacy III (2000-2003 year). Manual - part 844

PS-64

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [RHD MODEL]

28) Install a new boot band. Using band clamp pli-
ers, caulk the boot band to make clearance of
caulking part 2 mm (0.079 in) or less.

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

30) After installing, check the boot end is posi-
tioned into groove on tie-rod.

31) If the tie-rod end was removed, screw in the
lock nut and tie-rod end to screwed portion of tie-
rod, and then tighten the lock nut temporarily in a
position as shown in the figure.

Installed tie-rod length: L

15 mm (0.59 in)

(1) Boot band

(2) 2 mm (0.079 in) or less

(1) Clip

(2) 2 mm (0.079 in) or less

PS-00195

(1)

(2)

PS-00096

( 1 )

PS-00097

L

PS-65

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 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 serration

If bend or damage is excessive, replace entire gear-
box.

2

Dust seal

(1) Crack or damage
(2) Wear

If 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 “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 entire gearbox.

4

Gearbox unit

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

Replace gearbox with new one.

(4) Wear or damage on rack bush

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

(5) Wear on input shaft bearing

If free plays of input shaft in radial and axial direc-
tions are out of the specified ranges, replace gear-
box with 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

Pipes

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

Replace.

PS-66

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 gearbox by us-
ing ST. Never vise gearbox by inserting aluminum
plates, etc. between vise and gearbox.
ST

926200000

STAND

Sliding resistance of rack shaft:

Service limit

304 N (31 kgf, 68 lb) or less

Difference between left and right sliding resis-
tance

Less than 20%

3. RACK SHAFT PLAY IN RADIAL DIREC-
TION

Right-turn steering:

Service limit

Less than 0.4 mm (0.016 in) (direction 

)

Less than 0.6 mm (0.024 in)  (direction 

)

On condition

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

Left-turn steering:

Service limit

Less than 0.4 mm (0.016 in) (direction 

 

and )

On condition

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

(1) Right turn steering

(1) Left turn steering

PS-00324

( 1 )

PS-00325

( 1 )

(1) Lower side

(2) Right turn

(3) Measuring point

(4) Right

(1) Lower side

(2) Left turn

(3) Measuring point

(4) Left

PS-00326

P

L

L

( 1 )

( 2 )

( 3 )

( 4 )

P

PS-00327

L

L

( 1 )

( 2 )

( 3 )

( 4 )

PS-67

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [RHD MODEL]

4. INPUT SHAFT PLAY

In radial direction:

Service limit

0.18 mm (0.0071 in) or less

On condition

P: 98 N (10 kgf, 22 lb)

In axial direction:

Service limit

0.27 mm (0.0106 in) or less

On condition

P: 20 — 49 N (2 — 5 kgf, 4 — 11 lb)

5. TURNING RESISTANCE OF GEARBOX

Using ST, measure gearbox turning resistance.
ST

926230000

SPANNER

Service limit:

Straight-ahead position within 30 mm (1.18 
in) from rack center

Less than 11.18 N (1.14 kgf, 2.51 lb)

Maximum allowable resistance

15.79 N (1.61 kgf, 3.55 lb) or less

Difference between left and right sliding resis-
tance:

Less than 20%

PS-00328

P

PS-00329

P

PS-00330

ST