SUBARU LEGACY 1999 Service Repair Manual

2. AWD AT FRONT DRIVE SHAFT
1) Place alignment marks on shaft and outer race.
B4M0774
2) Remove SFJ boot band and boot.
CAUTION:
Be careful not to damage boot.
B4M0775A
3) Remove circlip from SFJ outer race using
screwdriver.
B4M0776
4) Remove SFJ outer race from shaft assembly.
5) Wipe off grease.
CAUTION:
The grease is a special grease. Do not confuse
with other greases.6) Place alignment mark on free ring and trunnion.
B4M0777
7) Remove free ring from trunnion.
8) Place alignment mark on trunnion and shaft.
B4M0778
9) Remove snap ring and trunnion.
B4M0779
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
10) Remove SFJ boot.
25
[W3B2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

11) Place drive shaft in a vise between wooden
blocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.
12) Raise boot band claws by means of screw-
driver and hammer.
B4M0689A
13) Cut and remove the boot.
CAUTION:
The boot must be replaced with a new one
whenever it is removed.
B4M0690
14) Thus, disassembly of axle is completed, but
BJ cannot be disassembled.
3. REAR DRIVE SHAFT
1) Straighten bent claw of larger end of DOJ boot.2) Loosen band by means of screwdriver or pliers
with care of not damaging boot.
G4M0281
3) Remove boot band on the small end of DOJ
boot in the same manner.
4) Remove the larger end of DOJ boot from DOJ
outer race.
5) Pry and remove round circlip located at the
neck of DOJ outer race with a screwdriver.
G4M0282
6) Take out DOJ outer race from shaft assembly.
7) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for con-
stant velocity joint). Do not confuse with other
greases.
NOTE:
Disassemble exercising care not to lose balls (6
pcs).
B4M0227C
8) To remove the cage from the inner race, turn
the cage by a half pitch to the track groove of the
inner race and shift the cage.
26
4-2[W3B3]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

9) Remove snap ring, which fixes inner race to
shaft, by using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ
boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
12) Remove BJ boot in the same procedure as
DOJ boot.
13) Thus, disassembly of axle is completed, but
BJ is unable to be disassembled.
C: INSPECTION
Check the removed parts for damage, wear, corro-
sion etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and
excessive play.
2) SFJ (Shudder-less Freering tripod Joint)
Check seizure, corrosion, damage and excessive
play.
3) Shaft
Check excessive bending, twisting, damage and
wear.
4) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
D: ASSEMBLY
1. EXCEPT AWD AT FRONT DRIVE SHAFT
CAUTION:
Use specified grease.
BJ side:
NTG2218 (Part No. 28093AA020)
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
1) Place BJ boot and small boot band on BJ 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 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
27
[W3D1]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

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 DOJ boot at the center of shaft.
10) Insert DOJ cage onto shaft.
NOTE:
Insert the cage with the cut-out portion facing the
shaft end, since the cage is directional.
G4M0284
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.
G4M0285
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.
B4M0228C
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 previously installed, and then fit outer
race.
B4M0227C
28
4-2[W3D1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

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

E: INSTALLATION
1. FRONT DRIVE SHAFT
1) Insert BJ 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.
G4M0291
3) Tighten axle nut temporarily.
4) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
5) Connect transverse link to housing.
Tightening torque (self-locking nut):
49
±10 N´m (5.0±1.0 kg-m, 36±7 ft-lb)
CAUTION:
Use a new self-locking nut.
6) Install stabilizer bracket.
7) While depressing brake pedal, tighten axle nut
to the specified torque.
Tightening torque:
186
±20 N´m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
IUse a new axle nut.
IAlways tighten axle nut before installing
wheel on vehicle. If wheel is installed andcomes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
IBe sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
8) After tightening axle nut, lock it securely.
2. REAR DRIVE SHAFT
1) Insert BJ into rear housing 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.
G4M0293
3) Tighten axle nut temporarily.
4) Replace circlips from DOJ spline with new one.
(2200 cc AT vehicles only)
5) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0549A
34
4-2[W3E1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts