Subaru Legacy (2005 year). Manual — part 844

PS-47

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD Model]

6. Steering Gearbox [RHD Mod-

el]

A: REMOVAL

1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Loosen the front wheel nuts.
4) Lift-up the vehicle, and remove the front wheels.
5) Remove the under cover. <Ref. to EI-26, RE-
MOVAL, Front Under Cover.>
6) Remove the front exhaust pipe assembly. (Non-
turbo model) <Ref. to EX(H4SO 2.0)-6, REMOVAL,
Front Exhaust Pipe.>

WARNING:
Be careful, not to burn yourself because the ex-
haust pipe is hot directly after driving.

7) Using a puller, remove the tie-rod end from the
knuckle arm after pulling off cotter pin and remov-
ing castle nut.

8) Remove the front crossmember support plate,
jack-up plate and front stabilizer. <Ref. to FS-15,
REMOVAL, Front Stabilizer.>
• Large type

• Small type

• Small type (6MT model)

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

10) Remove the universal joint. <Ref. to PS-22,
REMOVAL, Universal Joint.>

(1) Castle nut

(2) Tie-rod end

(3) Knuckle arm

(1) Front crossmember support plate

PS-00043

PS-00445

(1)

(1) Front crossmember support plate

(2) Jack-up plate

(1) Crossmember support plate

(2) Jack-up plate

(1) Pipe A

(2) Pipe B

FS-00105

(2)

(1)

(1)

FS-00186

(2)

(1)

(1)

PS-00446

(1)

(2)

PS-48

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD Model]

11) Disconnect the return hose and pressure hose
from gearbox.

12) Remove the clamp bolts securing gearbox to
the 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) Return hose

(2) Pressure hose

(1) Clamp

PS-00536

(1)

(2)

(1)

PS-00448

(1) Bracket

(1) Bracket

(1) Clamp

(1)

PS-00449

(1)

PS-00449

(1)

PS-00448

PS-49

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD Model]

5) Connect the return hose and pressure hose to
gearbox.

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, 66.4 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) Return hose

(2) Pressure hose

PS-00536

(1)

(2)

(A) Cotter pin

(B) Castle nut

(C) Tie-rod end

DS-00042

(C)

(B)

(A)

PS-50

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD 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) Disconnect the pipes A and B from steering body
and control valve housing.

2) Secure the gearbox removed from vehicle in a
vise using ST.
ST1

926200000

STAND

ST2

34199AG000 BOSS D

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

3) Remove the tie-rod end and lock nut from gear-
box.
4) Remove the clip from outside boot using pliers,
and then move the boot to tie-rod end side.

(1) Pipe A

(2) Pipe B

PS-00051

PS-00496

(1)

(2)

(1) Clamp

(1) Clip

PS-00492

(1)

ST1

ST2

PS-00053