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Front Drive Shaft: Disassembly

WARNING: This page is about a different car, the 2008 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Place alignment marks on the shaft and outer race.
    Fig 1: Identifying Alignment Marks On Shaft And Outer Race
    G05032644Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the AAR boot band and boot.
    CAUTION: Be careful not to damage the boot.
    Fig 2: Removing AAR Boot Band And Boot
    G05032645Courtesy of SUBARU OF AMERICA, INC.
  3. Place the drive shaft between wooden blocks and fix it on a vise.
    CAUTION: Do not fix the drive shaft on a vise directly.
    Fig 3: Placing Drive Shaft Between Wooden Blocks
    G05662705Courtesy of SUBARU OF AMERICA, INC.
  4. Tap the staking are of the outer race alternately with a plastic or wooden bar, and remove one roller at a time.
    Fig 4: Tapping Outer Race Of Staking
    G05662706Courtesy of SUBARU OF AMERICA, INC.
    CAUTION:
    • Tap the staking area (A) of the outer race.
    • Do not use a metal bar as the outer race may deform.
    • Be careful not to damage the roller parts.
    Fig 5: Tapping Staking Area Of Outer Race
    G05662707Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the outer race from shaft assembly.
    CAUTION: Make sure to have your associate held the outer race when removing the third roller to prevent the outer race from falling.
  6. Wipe off grease.
    CAUTION: The grease is a special type of grease. Do not mix with other grease.
  7. Place alignment marks on the roller kit and trunnion.
    Fig 6: Placing Alignment Marks On Roller Kit And Trunnion
    G05032647Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the roller kit from trunnion.
    CAUTION: Be careful with the roller kit position.
  9. Place alignment marks on the trunnion and shaft.
    Fig 7: Placing Alignment Marks On Trunnion And Shaft
    G05032648Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the snap ring and trunnion.
    Fig 8: Identifying Snap Ring And Trunnion
    G05032649Courtesy of SUBARU OF AMERICA, INC.
    CAUTION: Be sure to wrap shaft splines with vinyl tape to protect the boot from scratches.
  11. Remove the AAR boot.
NOTE: The AC is a non-disassembly part, so the drive shaft disassembly stops here.
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