Subaru Legacy (2005 year). Service manual — part 839

PS-27

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

11) Disconnect the pipe C from pressure hose first,
and pipe D from return hose second.

12) Remove the clamp bolts securing gearbox to
crossmember, and remove the clamp.

13) Remove the bolts which secure gearbox brack-
et, and remove the bracket and gearbox.

B: INSTALLATION

1) Insert the gearbox into crossmember, being
careful not to damage gearbox boot.
2) Install the gearbox and bracket. Tighten the bolt
temporarily.

3) Tighten the gearbox to the crossmember bracket
via clamp with bolt temporarily.

4) Tighten the bolts which temporary tightening the
clamp and bracket of gearbox to specified torque.

Tightening torque:

60 N

⋅

m (6.1 kgf-m, 44.1 ft-lb)

(1) Pipe C

(2) Pipe D

(3) Pressure hose

(4) Return hose

(1) Clamp

PS-00538

(4)

(3)

(2)

(1)

PS-00554

(1)

(1) Bracket

(1) Bracket

(1) Clamp

(1)

PS-00555

(1)

PS-00555

PS-00554

(1)

PS-28

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

5) Connect the pipe D to return hose first, and the
pipe C to pressure hose second.

Tightening torque:

15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

6) Install the universal joint. <Ref. to PS-22, IN-
STALLATION, Universal Joint.>
7) Connect the tie-rod end and knuckle arm, and
tighten with castle nut.

Castle nut tightening torque:

27 N

⋅

m (2.75 kgf-m, 19.9 ft-lb)

CAUTION:
When connecting, do not hit cap at the bottom
of tie-rod end with hammer.

8) After tightening the castle nut to the specified
tightening torque, tighten it further within 60

° until

cotter pin hole is aligned with slot in the nut. Fit the
cotter pin into nut, and then bend the pin to lock.

9) Install the front stabilizer. <Ref. to FS-15, IN-
STALLATION, Front Stabilizer.>
10) Install the front crossmember support plate and
jack-up plate.
11) Install the front exhaust pipe assembly. (Non-
turbo model) <Ref. to EX(H4SO 2.0)-7, INSTALLA-
TION, Front Exhaust Pipe.>
12) Install the under cover. <Ref. to EI-26, INSTAL-
LATION, Front Under Cover.>
13) Install the front wheels.
14) Tighten the wheel nuts to the specified torque.

Tightening torque:

90 N

⋅

m (9.2 kgf-m, 65.7 ft-lb)

15) Lower the vehicle.
16) Remove the steering wheel. <Ref. to PS-21,
REMOVAL, Steering Wheel.>
17) Align the center of roll connector. <Ref. to AB-
25, ADJUSTMENT, Roll Connector.>
18) Install the steering wheel. <Ref. to PS-21, IN-
STALLATION, Steering Wheel.>
19) Connect the ground cable to battery.
20) Pour fluid into the oil tank, and bleed air. <Ref.
to PS-91, Power Steering Fluid.>
21) Check for fluid leaks.
22) Check the fluid level in oil tank.

(1) Pipe C

(2) Pipe D

(3) Pressure hose

(4) Return hose

PS-00538

(4)

(3)

(2)

(1)

(A) Cotter pin

(B) Castle nut

(C) Tie-rod end

DS-00042

(C)

(B)

(A)

PS-29

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

23) After adjusting toe-in and steering angle, tight-
en the lock nut on tie-rod end.

Tightening torque:

85 N

⋅

m (8.7 kgf-m, 62.7 ft-lb)

NOTE:
When adjusting toe-in, hold the boot as shown to
prevent it from being rotated or twisted. If twisted,
straighten it.

C: DISASSEMBLY

1. RACK HOUSING ASSEMBLY

1) Disconnect the four pipes from gearbox.

NOTE:
Remove the pipes C and D, which are fixed to
clamp plate, as a unit.
2) Secure the gearbox removed from vehicle in a
vise using ST.
ST1

926200000

STAND

ST2

34199AG000 BOSS D

CAUTION:
Secure the gearbox in a vise using ST as
shown. Do not secure the gearbox assembly
without this ST.

3) Remove the tie-rod end and lock nut from gear-
box.

4) Remove the small clip from the boot using pliers,
and then move the boot to tie-rod end side.

5) Using a flat tip screwdriver, remove the band
from boot.

NOTE:
Replace the boot if there is damage, cracks or de-
terioration.

6) Using the ST, loosen the lock nut.
ST

926230000

SPANNER

(1) Clamp

PS-00051

PS-00492

(1)

ST1

ST2

(1) Clip

(1) Band

(1) Lock nut

PS-00661

(1)

PS-00509

(1)

PS-00494

ST

(1)

PS-30

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [LHD Model]

7) Tighten the adjusting screw until it no longer
tightens.

8) While securing the rack with a wrench (22 mm),
remove the tie-rod using a wrench (32 mm (1.26
in)) or adjustable wrench.

9) Loosen the adjusting screw and remove the
spring and sleeve.
10) Remove the two bolts securing valve assem-
bly.

11) Carefully draw out the input shaft and remove
the valve assembly.

12) Using a drill, release the caulking of holder.

CAUTION:
Make a hole of 2 mm (0.08 in) depth using a drill
with 3 mm (0.12 in) diameter.

13) Remove the holder using a 36 mm spanner or
adjustable wrench.

14) Remove the rack bushing and rack stopper
from rack assembly.
15) Remove the oil seal from rack.

(1) Adjusting screw

PS-00495

(1)

PS-00511

PS-00116

(1) Holder

PS-00117

PS-00516

PS-00512

(1)