SUBARU LEGACY 1997 Service Repair Manual

B4M0778
8) Place alignment mark on trunnion and shaft.
B4M0779
9) Remove snap ring and trunnion.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to prevent
boot from scratches.
10) Remove FTJ boot.
11) Remove BJ boot band and boot.
C: INSPECTION
Check the removed parts for damage, wear, corrosion and
etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and excessive
play.
2) Shaft
Check excessive bending, twisting, damage and wear.
3) UFJ (Under cut Free Joint)
Check seizure, corrosion, damage and excessive play.
4) Boot
Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.
34
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

D: ASSEMBLY
1. AWD MODEL
Use specified grease.
UFJ/BJ side:
UFJ (Front)—NTG2218 (Part No. 28093AA020)
BJ (Rear)—Molylex No. 2 (Part No. 723223010) or
Sunlight TB2-A
DOJ side:
AT model (Front and Rear) and MT model (Rear)
—VU-3A702 (Yellow)
(Part No. 23223GA050)
MT model (Front)—Molylex No. 2 (Part No.
723223010) or Sunlight TB2-A
1) Install BJ boot in specified position, and fill it with 60 to
70 g (2.12 to 2.47 oz) of specified grease.
2) Place DOJ boot at the center of shaft.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to prevent
boot from scratches.
G4M0284
3) Insert DOJ cage onto shaft.
NOTE:
Insert the cage with the cut-out portion facing the shaft end,
since the cage has an orientation.
G4M0285
4) Install DOJ inner race on shaft and fit snap ring with
pliers.
NOTE:
Confirm that the snap ring is completely fitted in the shaft
groove.
B4M0228A
5) Install cage, which was previously fitted, to inner race
fixed upon shaft.
NOTE:
Fit the cage with the protruded part aligned with the track
on the inner race and then turn by a half pitch.


1Inner race


2Cage
35
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

B4M0227A
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into
the interior of DOJ outer race.
7) Apply a coat of specified grease to the cage pocket and
six balls.
8) Insert six balls into the cage pocket.
9) Align the outer race track and ball positions and place
in the part where shaft, inner race, cage and balls are pre-
viously installed, and then fit outer race.


1Outer race


2Grease
G4M0282
10) Install circlip in the groove on DOJ outer race.
NOTE:
Assure that the balls, cage and inner race are com-
pletely fitted in the outer race of DOJ.
Exercise care not to place the matched position of circlip
in the ball groove of outer race.
Pull the shaft lightly and assure that the circlip is com-
pletely fitted in the groove.
11) Apply an even coat of the specified grease [20 to 30 g
(0.71 to 1.06 oz)] to the entire inner surface of boot. Also
apply grease to shaft.
12) Install DOJ boot taking care not to twist it.
NOTE:
The inside of the larger end of DOJ boot and the boot
groove shall be cleaned so as to be free from grease and
other substances.
When installing DOJ boot, position outer race of DOJ at
center of its travel.
13) Put a band through the clip and wind twice in align-
ment with band groove of boot.
CAUTION:
Use a new band.
14) Pinch the end of band with pliers. Hold the clip and
tighten securely.
NOTE:
When tightening boot, exercise care so that the air within
the boot is appropriate.
G4M0289
15) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
36
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

G4M0290
16) Tap on the clip with the punch provided at the end of
ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not dam-
aged.
17) Cut off band with an allowance of about 10 mm (0.39
in) left from the clip and bend this allowance over the clip.
CAUTION:
Be careful so that the end of the band is in close con-
tact with clip.
18) Fix up boot on BJ and UFJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease coating.
2. FWD MODEL
Use specified grease.
UFJ side:
UFJ (Front)—NTG2218 (Part No. 28093AA020)
DOJ side:
AT model (Front)—VU-3A702 (Yellow) (Part No.
23223GA050)
MT model (Front)—Molylex No. 2 (Part No.
723223010) or Sunlight TB2-A
1) Place UFJ boot and small boot band on UFJ side of
shaft.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to prevent
boot from scratches.
2) Place drive shaft in a vise.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden blocks.
3) Apply a coat of specified grease [60 to 70 g (2.12 to
2.47 oz)] to UFJ.
4) Apply an even coat of specified grease [20 to 30 g (0.71
to 1.06 oz)] to the entire inner surface of boot. Also apply
grease to shaft.
NOTE:
The inside of the larger end of UFJ boot and the boot
groove shall be cleaned so as to be free from grease and
other substances.
37
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

B4M0691A
5) Install boot projecting portion to UFJ groove.


1UFJ


2Large boot band


3Boot
6) Set large boot band in place.
B4M0692A
7) Align the boot end of the smaller diameter with the 3rd
groove in the drive shaft as shown in the figure.


1Boot


2Small boot band


3Shaft
B4M0693A
8) Tighten boot bands using ST, torque wrench and socket
flex handle.
ST 28099AC000 BOOT BAND PLIER


1Large boot band


2Boot


3Torque wrench


4Socket flex handle


5UFJ
Tightening torque:
Large boot band
152 N⋅m (16.0 kg-m, 116 ft-lb) or more
Small boot band
133 N⋅m (13.6 kg-m, 98 ft-lb) or more
9) Place DOJ boot at the center of shaft.
G4M0284
10) Insert DOJ cage onto shaft.
NOTE:
Insert the cage with the cut-out portion facing the shaft end,
since the cage is directional.
38
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

G4M0285
11) Install DOJ inner race on shaft and fit snap ring with
pliers.
NOTE:
Confirm that the snap ring is completely fitted in the shaft
groove.
B4M0228A
12) Install cage, which was previously fitted, to inner race
fixed upon shaft.
NOTE:
Fit the cage with the protruded part aligned with the track
on the inner race and then turn by a half pitch.


1Inner race


2Cage
B4M0227A
13) Put 80 to 90 g (2.82 to 3.17 oz) of specified grease into
the interior of DOJ outer race.
14) Apply a coat of specified grease to the cage pocket
and six balls.
15) Insert six balls into the cage pocket.
16) Align the outer race track and ball positions and place
in the part where shaft, inner race, cage and balls are pre-
viously installed, and then fit outer race.


1Outer race


2Grease
G4M0282
17) Install circlip in the groove on DOJ outer race.
NOTE:
Assure that the balls, cage and inner race are com-
pletely fitted in the outer race of DOJ.
Exercise care not to match the open end of circlip in the
ball groove of outer race.
Pull the shaft lightly and assure that the circlip is com-
pletely fitted in the groove.
18) Apply an even coat of specified grease [20 to 30 g
(0.71 to 1.06 oz)] to the entire inner surface of boot. Also
apply grease to shaft.
19) Install DOJ boot taking care not to twist it.
NOTE:
The inside of the larger end of DOJ boot and the boot
groove shall be cleaned so as to be free from grease and
other substances.
When installing DOJ boot, position outer race of DOJ at
center of its travel.
39
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

20) Put a band through the clip and wind twice in align-
ment with band groove of boot.
CAUTION:
Use a new band.
21) Pinch the end of band with pliers. Hold the clip and
tighten securely.
NOTE:
When tightening boot, exercise care so that the air within
the boot is appropriate.
G4M0289
22) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0290
23) Tap on the clip with the punch provided at the end of
ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap only to the extent that the boot underneath is not
damaged.
24) Cut off band with an allowance of about 10 mm (0.39
in) left from the clip and bend this allowance over the clip.
CAUTION:
Be careful so that the end of the band is in close con-
tact with clip.
25) Fix up boot on UFJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease coating.
40
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

3. FTJ
CAUTION:
Use specified grease.
BJ side:
NTG2218 (Part No. 28093AA020)
FTJ side:
SSG 6003
CAUTION:
Be sure to wrap shaft splines with vinyl tape to prevent
boot from scratches.
1) Install BJ boot in specified position and fill it with 60 to
70 g (2.12 to 2.47 oz) of specified grease.
CAUTION:
The inside of the larger end of BJ boot and the boot
groove must be cleaned so as to be free from grease
and other substances.
2) Place FTJ boot at the center of shaft.
B4M0778
3) Align alignment marks and install trunnion on shaft.
4) Install snap ring to shaft.
CAUTION:
Confirm that the snap ring is completely fitted in the
shaft groove.
5) Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease
into the interior of FTJ outer race.
6) Apply a coat of specified grease to free ring and trun-
nion.
B4M0777
7) Align alignment marks on free ring and trunnion and
install free ring.
41
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

B4M0774
8) Align alignment marks on shaft and outer race, and
install outer race.
9) Install circlip in the groove on FTJ outer race.
CAUTION:
Pull the shaft lightly and assure that the circlip is com-
pletely fitted in the groove.
10) Apply an even coat of the specified grease 30 to 40 g
(1.06 to 1.41 oz) to the entire inner surface of boot.
11) Install FTJ boot taking care not to twist it.
CAUTION:
The inside of the larger end of FTJ boot and the boot
groove shall be cleaned so as to be free from grease
and other substances.
When installing FTJ boot, position outer race of DOJ
at center of its travel.
12) Put a band through the clip and wind twice in align-
ment with band groove of boot.
CAUTION:
Use a new band.
13) Pinch the end of band with pliers. Hold the clip and
tighten securely.
NOTE:
When tightening boot, exercise care so that the air within
the boot is appropriate.
G4M0289
14) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0290
15) Tap on the clip with the punch provided at the end of
ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not dam-
aged.
42
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

16) Cut off band with an allowance of about 10 mm (0.39
in) left from the clip and bend this allowance over the clip.
CAUTION:
Be careful to that the end of the band is in close con-
tact with clip.
17) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract FTJ to provide equal grease coating.
G4M0291
E: INSTALLATION
1. FRONT DRIVE SHAFT
1) Insert UFJ (Under cut Free Joint) into hub splines.
CAUTION:
Be careful not to damage inner oil seal lip.
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
3) Tighten axle nut temporarily.
G4M0279
4) Install DOJ on transmission spindle and drive spring pin
into place.
CAUTION:
Always use a new spring pin.
43
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts