boot SUBARU LEGACY 1999 Service Owner's Manual

17) Install circlip in the groove on DOJ outer race.
NOTE:
IAssure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
IExercise care not to match the open end of cir-
clip in the ball groove of outer race.
IPull the shaft lightly and assure that the circlip is
completely fitted in the groove.
G4M0282
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:
IThe 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.
IWhen installing DOJ boot, position outer race of
DOJ at center of its travel.
20) Put a band through the clip and wind twice in
alignment 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.22) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0289
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.
G4M0290
24) Cut off band with an allowance of about 10
mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
CAUTION:
Be careful so that the end of the band is in
close contact with clip.
25) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coating.
2. AWD AT FRONT DRIVE SHAFT
CAUTION:
Use specified grease.
BJ side:
NTG2218 (Part No. 28093AA020)
SFJ side:
NTG30B (Part No. 28095AC000)
1) Place BJ boot and small boot band on BJ side
of shaft.
29
[W3D2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

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 BJ.
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 BJ boot and the boot
groove shall be cleaned so as to be free from
grease and other substances.
5) Install boot projecting portion to BJ groove.
B4M1296A
6) Set large boot band in place.
7) Install boot projecting portion to shaft groove.
B4M1297A
8) Tighten boot bands using ST, torque wrench
and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
B4M0693B
(1) Large boot band
(2) Boot
(3) Torque wrench
(4) Socket flex handle
(5) BJ
Tightening torque:
Large boot band
157 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 SFJ boot at the center of shaft.
10) Align alignment marks and install trunnion on
shaft.
B4M0778
11) Install snap ring to shaft.
CAUTION:
Confirm that the snap ring is completely fitted
in the shaft groove.
12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
grease into the interior of SFJ outer race.
13) Apply a coat of specified grease to free ring
and trunnion.
30
4-2[W3D2]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

14) Align alignment marks on free ring and trun-
nion and install free ring.
B4M0777
15) Align alignment marks on shaft and outer
race, and install outer race.
B4M0774
16) Install circlip in the groove on SFJ outer race.
CAUTION:
Pull the shaft lightly and assure that the circlip
is completely fitted in the groove.
17) 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.
18) Install SFJ boot taking care not to twist it.
CAUTION:
IThe inside of the larger end of SFJ boot and
the boot groove shall be cleaned so as to be
free from grease and other substances.
IWhen installing SFJ boot, position outer
race of SFJ at center of its travel.
19) Put a band through the clip and wind twice in
alignment with band groove of boot.CAUTION:
Use a new band.
20) 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.
21) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0289
22) 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
damaged.
G4M0290
23) Cut off band with an allowance of about 10
mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
CAUTION:
Be careful so that the end of the band is in
close contact with clip.
24) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract SFJ to provide equal grease
coating.
31
[W3D2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

3. REAR DRIVE SHAFT
CAUTION:
Use specified grease.
BJ side:
Molylex No. 2 (Part No. 723223010) or
Sunlight TB2-A
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
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.
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.
G4M0284
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.
G4M0285
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.
B4M0228C
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 previously installed, and then fit outer
race.
B4M0227C
32
4-2[W3D3]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

10) Install circlip in the groove on DOJ outer race.
NOTE:
IAssure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
IExercise care not to place the matched position
of circlip in the ball groove of outer race.
IPull the shaft lightly and assure that the circlip is
completely fitted in the groove.
G4M0282
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:
IThe 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.
IWhen installing DOJ boot, position outer race of
DOJ at center of its travel.
13) Put a band through the clip and wind twice in
alignment 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.15) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0289
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
damaged.
G4M0290
17) Cut off band with an allowance of about 10
mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
CAUTION:
Be careful so that the end of the band is in
close contact with clip.
18) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coating.
33
[W3D3]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

4. Replacement of Front SFJ,
DOJ and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
5) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
6) Remove SFJ, DOJ and BJ boots from drive
shaft. or [W3B2].>
B: INSTALLATION
1) Install SFJ, DOJ and BJ boots to drive shaft.
or
2) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
3) Connect transverse link to housing.
4) Install stabilizer link.
5. Replacement of Rear DOJ
and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
3) Remove ABS sensor clamps and parking brake
cable bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove bolts which secure trailing link assem-
bly to rear housing.
7) Remove crossmember reinforcement lower
from crossmember (4 door model only).
8) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
CAUTION:
Be careful not to damage side bearing retainer.
Always use bolt as shown in figure, as support-
ing point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0995
36
4-2[W4A0]SERVICE PROCEDURE
4. Replacement of Front SFJ, DOJ and BJ Boots

4. Replacement of Front SFJ,
DOJ and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
5) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
6) Remove SFJ, DOJ and BJ boots from drive
shaft. or [W3B2].>
B: INSTALLATION
1) Install SFJ, DOJ and BJ boots to drive shaft.
or
2) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
3) Connect transverse link to housing.
4) Install stabilizer link.
5. Replacement of Rear DOJ
and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
3) Remove ABS sensor clamps and parking brake
cable bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove bolts which secure trailing link assem-
bly to rear housing.
7) Remove crossmember reinforcement lower
from crossmember (4 door model only).
8) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
CAUTION:
Be careful not to damage side bearing retainer.
Always use bolt as shown in figure, as support-
ing point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0995
36
4-2[W4A0]SERVICE PROCEDURE
4. Replacement of Front SFJ, DOJ and BJ Boots

9) Remove DOJ from rear differential using tire
lever. (2200 cc AT vehicles)
NOTE:
The side spline shaft circlip comes out together
with the shaft.
G3M0257
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the axle shaft
holder.
G3M0045
10) Remove DOJ and BJ boots from drive shaft.

B: INSTALLATION
1) Install DOJ and BJ boots to drive shaft.

2) Replace circlips from DOJ spline with new one.
(2200 cc AT vehicles only)3) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0549A
4) Insert DOJ spline end into bore of side oil seal,
and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0550A
5) Align DOJ and differential splines.
6) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
CAUTION:
Discard old self-locking nut. Replace with a
new one.
7) Connect rear housing assembly to trailing link
assembly, and tighten self-locking nut.
8) Connect rear housing assembly to lateral link
37
[W5B0]4-2SERVICE PROCEDURE
5. Replacement of Rear DOJ and BJ Boots

2. Power Steering System
A: LHD MODEL
B4M1149B
(1) Clamp
(2) Adapter
(3) Hose bracket
(4) Pipe C
(5) Pipe D
(6) Clamp E
(7) Cap
(8) Strainer
(9) Seal washer
(10) Tank
(11) O-ring
(12) Oil pump
(13) Pulley
(14) Bracket
(15) Bush(16) Belt cover
(17) Clamp plate
(18) Pipe F
(19) Pipe E
(20) Universal joint
(21) Dust seal
(22) C-ring
(23) Oil seal
(24) Valve housing
(25) Packing
(26) Seal ring
(27) Pinion and valve ASSY
(28) Oil seal
(29) Back-up washer
(30) Ball bearing(31) Snap ring
(32) Lock nut
(33) Adjusting screw
(34) Spring
(35) Sleeve
(36) Adapter
(37) Clamp
(38) Cotter pin
(39) Castle nut
(40) Dust seal
(41) Clip
(42) Tie-rod end
(43) Small clip
(44) Boot
(45) Large clip
5
[C2A0]4-3COMPONENT PARTS
2. Power Steering System

B: RHD MODEL
B4M1150B
(1) Clamp
(2) Adapter
(3) Hose bracket
(4) Pipe C
(5) Pipe D
(6) Clamp E
(7) Cap
(8) Strainer
(9) Seal washer
(10) Tank
(11) O-ring
(12) Oil pump
(13) Pulley
(14) Bracket
(15) Bush
(16) Belt cover
(17) Universal joint(18) Dust cover
(19) Valve housing
(20) Y-packing
(21) Ball bearing
(22) Spacer
(23) Pinion
(24) Shim
(25) Adapter
(26) Clamp
(27) Castle nut
(28) Cotter pin
(29) Dust seal
(30) Clip
(31) Tie-rod end
(32) Clip
(33) Boot
(34) Wire(35) Tie-rod
(36) Lock washer
(37) Holder
(38) Bush
(39) Y-packing
(40) Oil seal
(41) O-ring
(42) Rack
(43) Oil seal
(44) Back-up washer
(45) Housing ASSY
(46) Pipe A
(47) Pipe B
(48) Lock nut
(49) Adjusting screw
(50) Spring
(51) Sleeve
7
[C2B0]4-3COMPONENT PARTS
2. Power Steering System