Rear Drive Shaft: Assembly

BJ side (outer joint): 

Molylex No. 2 (Part No. 723223010) 

DOJ side (inner joint): 

VU-3A702 (Yellow) (Part No. 23223GA050) 

1. Install outer joint boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 oz) of specified grease.
2. Place inner joint boot at the center of shaft.
   CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.
3. Insert inner joint cage onto shaft.
   NOTE: Insert the cage with the cut-out portion facing the shaft end, since the cage has an orientation.
   Fig 1: Installing Inner Joint Cage Onto Shaft

   Courtesy of SUBARU OF AMERICA, INC.
4. Install inner joint inner race on shaft and fit snap ring with snap ring pliers.
   NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
   Fig 2: Installing Snap Ring With Snap Ring Pliers

   Courtesy of SUBARU OF AMERICA, INC.
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.
   Fig 3: Installing Cage To Inner Race

   Courtesy of SUBARU OF AMERICA, INC.
6. Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the interior of inner joint 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.
   Fig 4: Installing Outer Race

   Courtesy of SUBARU OF AMERICA, INC.
10. Install circlip in the groove on inner joint outer race.
    NOTE:

    • Assure that the balls, cage and inner race are completely fitted in the outer race of inner joint.
    • 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 completely fitted in the groove.
    Fig 5: Installing Circlip In Groove On Inner Joint Outer Race

    Courtesy of SUBARU OF AMERICA, INC.
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 inner joint boot taking care not to twist it.
    CAUTION:

    • The inside of the larger end of inner joint boot and the boot groove shall be cleaned so as to be free from grease and other substances.
    • When installing inner joint boot, position outer race of inner joint at center of its stroke.
13. Put a band through the clip and wind twice in alignment with band groove of boot.
    CAUTION: The boot must be replaced with a new one whenever it is removed.
14. Tighten band by using ST.

    ST 925091000 BAND TIGHTENING TOOL

    NOTE: Tighten band until it cannot be moved by hand.
    Fig 6: Locating Band

    Courtesy of SUBARU OF AMERICA, INC.
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 damaged.
    Fig 7: Taping On Clip With Punch

    Courtesy of SUBARU OF AMERICA, INC.
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: Bend the band so that its end is in close contact with clip.
17. Fix up boot on outer joint in the same manner.
18. Extend and retract inner joint so that the grease in inner joint may spread equally.