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Rear Drive Shaft: Assembly

WARNING: This page is about a different car, the 2006 Subaru Outback and 2006 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Use specified grease.
  1. Install the BJ or EBJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 oz.) of specified grease.
  2. Place the DOJ boot at the center of shaft.
    CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.
  3. Insert the DOJ cage onto shaft.
    NOTE: Insert the cage with the cut-out portion facing the shaft end, since the cage has an orientation.
    Fig 1: Inserting Cage With Cut-Out Portion Facing Shaft End
    G03832785Courtesy of SUBARU OF AMERICA, INC.
  4. Install the DOJ inner race on shaft and fit the snap ring with pliers.
    NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
    Fig 2: Fitting Snap Ring
    G03832786Courtesy of SUBARU OF AMERICA, INC.
  5. Install the cage 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 Fixed Upon Shaft
    G03832787Courtesy of SUBARU OF AMERICA, INC.
  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 the shaft, inner race, cage and balls in the original positions and then fit outer race.
    Fig 4: Fitting Outer Race
    G03832788Courtesy of SUBARU OF AMERICA, INC.
  10. Install the snap ring in the groove on DOJ outer race.
    NOTE:
    • Assure that the balls, cage and inner race are completely fitted in the outer race of DOJ.
    • Use care not to place the matched position of snap ring 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 Snap Ring In Groove On DOJ Outer Race
    G03832789Courtesy 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 the DOJ boot taking care not to twist it.
    NOTE:
    • The 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.
    • When installing DOJ boot, position outer race of DOJ at center of its travel.
  13. Put a new band through the clip and wind twice in alignment with band groove of boot.
  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 the band by using ST.

    ST 925091000 BAND TIGHTENING TOOL

    NOTE: Tighten the band until it cannot be moved by hand.
    Fig 6: Locating Boot Band
    G03832790Courtesy of SUBARU OF AMERICA, INC.
  16. Tap on the clip with the punch provided at the end of ST.

    ST 925091000 BAND TIGHTENING TOOL

    NOTE: Tap to an extent that the boot underneath is not damaged.
    Fig 7: Tapping On Clip
    G03832791Courtesy of SUBARU OF AMERICA, INC.
  17. Cut off the band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip.
    NOTE: Be careful so that the end of the band is in close contact with clip.
  18. Install the BJ boot or EBJ boot in the same procedure as DOJ boot.
  19. Extend and retract the DOJ to provide equal grease coating.
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