Front Drive Shaft: Assembly

Grease: 

AARi side 

One Lube C (Part No. 28395SA000) 

1. Fit the AARi boot and retainer to shaft, and then position to center of shaft.
2. Align the alignment marks, and then install the trunnion on shaft.
   Fig 1: Installing Trunnion On Shaft

   Courtesy of SUBARU OF AMERICA, INC.
3. Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of AARi outer race.
4. Apply a coat of specified grease to the free ring and trunnion.
5. Align the alignment marks on shaft and outer race, and then install the outer race.
   Fig 2: Aligning Marks On Shaft And Outer Race

   Courtesy of SUBARU OF AMERICA, INC.
6. 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.
7. Install the AARi boot taking care not to twist it.
   CAUTION:

   • The inside of the larger end of AARi boot and boot groove shall be cleaned so as to be free from grease and other substances.
   • When installing the AARi boot, position the outer race of AARi at center of its travel.
8. Make sure to recognize the position of retainer.
   Fig 3: Positioning Of Retainer

   Courtesy of SUBARU OF AMERICA, INC.
9. Install a new large boot band and small boot band in specified position.
10. Using the ST, torque wrench and socket flex handle, tighten the boot band.

    ST 28099AC000 BOOT BAND PLIERS

    Fig 4: Locating Large Boot Band And Small Boot Band Using Boot Band Pliers ST 28099AC000

    Courtesy of SUBARU OF AMERICA, INC.

    Caulked portion clearance of boot band: 

    Large boot band 

    1 mm (0.04 in) or less 

    Small boot band 

    1 mm (0.04 in) or less 

11. Extend and retract repeatedly the AARi to provide equal grease coating.