Subaru Legacy III (2000-2003 year). Manual - part 845

PS-68

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [RHD MODEL]

6. OIL LEAKING

• Oil leaking points

1) If leak point is other than a, b, c, or d, perform the
5th step  in “Oil leak check procedure and replace-
ment parts” before dismounting gearbox from vehi-
cle.  <Ref. to “Oil leak check procedure and
replacement parts”.> 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 run-
ning, then make comparison of the suspected por-
tion 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 ar-
eas again.
• 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 inevita-
ble 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 “a”
The oil seal is damaged. Replace valve assembly
with a new one.
2) Leakage from “b”
The torsion bar O-ring is damaged. Replace valve
assembly with a new one.
3) Leakage from “c”
The oil seal is damaged. Replace oil seal with a
new one.
4) Leakage from “d”
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 leak-
ing from the gearbox, move the right and left boots
toward tie-rod end side, respectively, with the gear-
box mounted to the vehicle, and remove oil from
the surrounding portions. Then, turn the steering
wheel from lock to lock 30 to 40 times with the en-
gine running, then make comparison of the leaked
portion immediately after and several hours after
this operation.

(1) Leakage from “e”
The cylinder seal is damaged. Replace rack
bush with a new one.

(1) Power cylinder

(3) Rack piston

(5) Input shaft

(2) Cylinder

(4) Rack

(6) Valve housing

PS-00331

a

b

d

c

c

d

d

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

PS-69

POWER ASSISTED SYSTEM (POWER STEERING)

STEERING GEARBOX [RHD MODEL]

(2) Leakage from “f”
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
comparison of the leaked portion between im-
mediately after and several hours after this op-
eration.

CAUTION:
• If leakage from “f” 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.
• If oil stops leaking from “f”: 
The oil seal of rack housing is damaged. Re-
place the oil seal and the parts that are dam-
aged during disassembly with new ones.

F: ADJUSTMENT

1) Adjust front toe.

Standard of front toe:

IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12 in)

2) Adjust steering angle of wheels.

Standard of steering angle:

3) If steering wheel spokes are not horizontal when
wheels are set in the straight ahead position, and
error is more than 5

°

 on the periphery of steering

wheel, correctly re-install the steering wheel.

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.

(1) Lock nut

Model

Except OUTBACK

OUT-

BACK

15 inch 

wheel

16 inch wheel

Inner 
wheel

37.5

°±

1.5

°

36.3

°±

1.5

°

34.5

°±

1.5

°

Outer 
wheel

32.6

°±

1.5

°

31.6

°±

1.5

°

30.3

°±

1.5

°

PS-00332

( 1 )

PS-00108

0 – 17 mm
(0 – 0.67 in)

PS-00273

PS-70

POWER ASSISTED SYSTEM (POWER STEERING)

PIPE ASSEMBLY

7. Pipe Assembly

A: REMOVAL

1) Set the vehicle on the lift.
2) Disconnect battery ground cable.
3) Lift vehicle and remove jack-up plate.

4) Remove one pipe joint at the center of gearbox,
and connect vinyl hose to pipe and joint. Discharge
fluid by turning steering wheel fully clockwise and
counterclockwise. Discharge fluid similarly from the
other pipe.

CAUTION:
Improper removal and installation of parts often 
causes fluid leak trouble. To prevent this, clean 
the surrounding portions before disassembly 
and reassembly, and pay special attention to 
keep dirt and other foreign matter from mating 
surfaces.
LHD model

RHD model

5) Remove clamp E from pipes.
LHD model

(1) Jack-up plate

(1) Pipe A

(2) Pipe B

PS-00044

( 1 )

PS-00026

( 1 )

( 2 )

(1) Pipe A

(2) Pipe B

(1) Return hose

(2) Pressure hose

(3) Clamp E

(4) Pipe C

(5) Pipe D

PS-00333

( 1 )

( 2 )

( 3 )

PS-00176

( 1 )

( 2 )

( 4 )

( 5 )

PS-71

POWER ASSISTED SYSTEM (POWER STEERING)

PIPE ASSEMBLY

RHD model (Except 3.0 L)

6) Disconnect pipe C·D.
LHD model
Disconnect pipe C·D from pipe (on the gearbox
side).

CAUTION:
• When disconnecting pipe C·D, use two
wrenches to prevent deformities.
• Be careful to keep pipe connections free from
foreign matter.

RHD model
Remove flare nuts from control valve of gearbox
assembly, and then disconnect pipe.

CAUTION:
• When disconnecting pipes, use two wrench-
es to prevent deformities.
• Be careful to keep pipe connections free from
foreign matter.

7) Lower the vehicle.
8) Remove intake duct.
9) Remove bolt A.
Except 3.0 L and Turbo model
Disconnect pipe C from oil pump. Disconnect pipe
D from return hose.

CAUTION:
• Do not allow fluid from the hose end to come
into contact with pulley belt.
• To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.

(1) Pressure hose

(2) Return hose

(3) Clamp E

(4) Pipe C

(5) Pipe D

(1) Pipe C

(2) Pipe D

PS-00335

( 3 )

( 5 )

( 2 )

( 1 )

( 4 )

( 1 )

( 2 )

PS-00205

(1) Bolt A

(2) Pipe C

(3) Pipe D

PS-00288

( 1 )

( 2 )

( 3 )

PS-00221