Rear Drive Shaft: Assembly

Grease: 

EDJ, DOJ side: NKG814

BJ side, DOJ side: NKG814

1. Install the BJ or EBJ boot in specified position on the shaft assembly, and fill it with 50 - 60 g (1.76-2.12 oz) of specified grease.
2. Install the DOJ inner race to the shaft.
   1. Install the DOJ or EDJ boot onto shaft.
   2. Insert the cage onto shaft.
      NOTE: Insert the cage with the cutout portion facing the shaft end, since the cage has an orientation.
      Fig 1: Identifying Cage And Cutout Portion

      Courtesy of SUBARU OF AMERICA, INC.
   3. Install the inner race on shaft and fix the snap ring in place with pliers.
      NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
   Fig 2: Fixing Snap Ring Using Pliers

   Courtesy of SUBARU OF AMERICA, INC.
3. Install the cage, which is already inserted into the shaft assembly to the inner race.
   1. Install the cage (B) with the protruding section aligned with the track on the inner race (A), and turn by a half pitch.
      Fig 3: Identifying Inner Race And Cage

      Courtesy of SUBARU OF AMERICA, INC.
   2. Fill 80 - 90 g (2.82-3.17 oz) of specified grease into the inner side of the DOJ or EDJ outer race.
   3. Apply a thin coat of specified grease to the cage pocket and ball.
   4. Insert the ball bearings into the cage pocket.
4. Connect the outer race to the shaft assembly.
   1. Align the outer race track and ball positions, and place the shaft, inner race, cage and ball bearings in the original positions, and then fix outer race in place.
      Fig 4: Identifying Outer Race And Grease

      Courtesy of SUBARU OF AMERICA, INC.
   2. Install the snap ring in the groove on the DOJ outer race.
      CAUTION: Be careful of the following items during installation:

      • Make sure that the balls, cage and inner race are completely fitted in the outer race of DOJ.
      • Use care not to place the matched position of snap ring in the ball groove of outer race.
      • Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
   3. Apply an even coat of the specified grease [20 - 30 g (0.71-1.06 oz)] to the entire inner surface of boot. Also apply grease to the shaft.
   4. Install the DOJ boot and EDJ boot taking care not to twist it.
   NOTE:

   • The inside of the large end of DOJ or EDJ boot and the boot groove shall be cleaned so as to be free from grease and other substances.
   • When installing the DOJ or EDJ boot, position the outer race of DOJ or EDJ boot at center of the stroke.
5. Tighten the boot band. (double loop type)
   CAUTION:

   • Be careful not to damage the boot.
   • When tightening boot, use care so that the air within the boot is appropriate.
   • Once assembled, extend and retract the DOJ repeatedly to provide an equal coating of grease.
   1. Put a new band through the clip and wind twice in the band groove of the boot.
   2. Pinch the end of band with pliers. Hold the clip and tighten securely.
   3. Tighten the band using the ST.
      NOTE: Tighten the band until it cannot be moved by hand.

      Preparation tool: 

      ST: BAND TIGHTENING TOOL (925091000)

      Fig 5: Tightening Band Using ST

      Courtesy of SUBARU OF AMERICA, INC.
   4. Tap the clip with the punch provided at the end of the ST.
      NOTE: Tap to an extent that the boot underneath is not damaged.

      Preparation tool: 

      ST: BAND TIGHTENING TOOL (925091000)

      Fig 6: Tapping Clip With Punch Provided At End Of ST

      Courtesy of SUBARU OF AMERICA, INC.
   5. Cut off the band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip.
      CAUTION: Make sure that the end of the band is in close contact with clip.
6. Tighten the boot band. (locking tab type)
   CAUTION:

   • Be careful not to damage the boot.
   • When tightening boot, use care so that the air within the boot is appropriate.
   • Once assembled, extend and retract the DOJ repeatedly to provide an equal coating of grease.

   Preparation tool: 

   Needle nose pliers

   1. Place a new band onto the groove of the boot.
   2. Pinch (e) and (d) of the band with needle nose pliers, and align with the convex claw (c) for temporarily tightening position.
   3. Keep tightening until claw (a) is seen through the claw window (f) and hold.
   4. While holding the end of the band, hook the claw (a) with the claw window (f).
   5. Make sure the claw (a) and claw (b) are both securely engage to the claw window.
   Fig 7: Tightening Band Using Needle Nose Pliers

   Courtesy of SUBARU OF AMERICA, INC.
7. Extend and retract the DOJ or EDJ repeatedly to provide an equal coating of grease.