Subaru Legacy IV (2008 year). Manual - part 968

PS-34

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

E: INSPECTION

1. BASIC INSPECTION

1) Clean all the 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.

2. SERVICE LIMIT

Make a measurements as follows. If it exceeds the
specified service limits, 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

No.

Parts

Inspection

Corrective action

Input shaft

(1) Bent input shaft
(2) Damage on serration

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

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 part.

Rack & pinion

Poor mating of rack with pinion

(1) Adjust the backlash properly.
By measuring the turning torque of the gearbox and slid-
ing resistance of rack, check if the rack & pinion engage
uniformly and smoothly with each other. (Refer to Service
limit.)
(2) Pull out the entire rack to allow viewing of the teeth,
and check for damage.
Even if abnormality is found in either (1) or (2), replace
the entire gearbox.

Gearbox unit

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

Replace the gearbox with a new part.

(4) Wear or damage on rack bush-
ing

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

(5) Wear on input shaft bearing

If the free play of input shaft in radial and axial direction is
out of the specified range, replace the gearbox with a new
part. (Refer to Service limit.)

Boot

Crack, damage or deterioration

Replace.

Tie-rod

(1) Looseness of ball joint
(2) Bend of tie-rod

Replace.

Tie-rod end

Damage or deterioration of dust
seal

Replace.

Adjusting screw
spring

Deterioration

Replace.

Boot clip

Deterioration

Replace.

Sleeve

Damage

Replace.

Pipe

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

Replace.

PS-35

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

3. RACK SHAFT PLAY IN THE RADIAL
DIRECTION

Right-turn steering:

Service limit

0.12 mm (0.005 in) or less

On condition

Weighting point

L1: 10 mm (0.39 in)
P: 98 N (10 kgf, 22 lb)

Measuring point

L2: 25 mm (0.98 in)

4. INPUT SHAFT PLAY

In radial direction:

Service limit

0.26 mm (0.01 in) or less

On condition

P: 98 N (10 kgf, 22 lb)

In axial direction:

Without play

5. TURNING RESISTANCE OF GEARBOX

Using the ST, measure the gearbox turning resis-
tance.
ST

34099PA100

SPANNER

Service limit:

Maximum allowable resistance:

11.3 N (1.15 kgf, 2.54 lb) or less.

Difference between right and left turning re-
sistance:

24% or less

PS-00769

PS-00103

PS-00104

PS-00105

PS-36

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

6. OIL LEAKAGE

1) Lift up the vehicle.
2) If a fluid leak is found, clean the fluid completely
from the suspect area, and turn the steering wheel
approx. 30 to 40 times to the left and right from lock
to lock, with the engine running, and check again
for leaks immediately, and also after a few hours
have passed.
3) Cause and solution for oil leakage from “a”
The oil seal is damaged. Replace the valve assem-
bly with a new part.
4) Cause and solution for oil leakage from “b”
The torsion bar O-ring is damaged. Replace the
valve assembly with a new part.
5) Cause and solution for oil leakage from “c”
The oil seal is damaged. Replace the valve assem-
bly or oil seal with a new part.
6) Cause and solution for oil leakage from “d”
The pipe is damaged. Replace the faulty pipe or O-
ring.
7) Cause and solution for oil leakage from “g”.
The hose is damaged. Replace the hose with a
new part.

8) If leak is other than a, b, c, d or g, or if oil is leak-
ing from gearbox, move the right and left boots to-
ward tie-rod end side, respectively, with the
gearbox mounted to the vehicle, and remove fluid
from surrounding portions. Then, turn the steering
wheel from lock to lock about 30 to 40 times with
the engine running, then re-inspect the leaking
area immediately after and several hours after this
operation.

(1) Leakage from “e”
The cylinder seal is damaged. Replace the rack
bushing with a new part.
(2) Leakage from “f”
There are two possible causes. Perform the fol-
lowing step first. Remove the pipe assembly B
from the valve housing, and close the circuit us-
ing ST.

926420000

PLUG

Turn the steering wheel from lock to lock ap-
prox. 30 to 40 times with the engine running,
then inspect the leaked portion immediately af-
ter and several hours after this operation.
• If leakage from “f” is noted again:
The oil seal of pinion and valve assembly is
damaged. Replace the pinion & valve assembly
with a new part. Or replace the oil seal and the
parts that are damaged during disassembly
with new parts.
• If oil stops leaking from “f”:
The oil seal of rack housing is damaged. Re-
place the oil seal and parts that are damaged
during disassembly with new parts.

(1)

Power cylinder

(3)

Rack piston

(5)

Input shaft

(2)

Cylinder

(4)

Rack axle

(6)

Valve housing

PS-00622

(4) (3) (2)

(5)

(6)

(1)

PS-37

Steering Gearbox

POWER ASSISTED SYSTEM (POWER STEERING)

F: ADJUSTMENT

1) Adjust the front toe.
<Ref. to FS-10, FRONT WHEEL TOE-IN, INSPEC-
TION, Wheel Alignment.>

Standard of front toe:

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

2) Adjust the steering angle of the wheels.

Standard of steering angle:

3) If the steering wheel spokes are not horizontal
when wheels are set in the straight ahead position,
or error is more than 5° on the periphery of the
steering wheel, correctly re-install the steering
wheel.

4) If the 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 opposite direction from each oth-
er by the same angle.

(1) Lock nut

Model

Except for 2.5 GT

spec.B and 3.0 R-LTD

2.5 GT spec.B and

3.0 R-LTD

Inner wheel

37.6°

r1.5°

33.8°

r1.5°

Outer wheel

33.0°

r1.5°

30.2°

r1.5°

(1) 5° or less

PS-00107

PS-00513

(1)

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