Rear Drive Shaft: Assembly

BJ side: 

NTG2218-M (Part No. 28395AG01A) 

EBJ side 

NKG106 (Part No. 28395AG04A) 

DOJ side: 

NKG205 (Part No. 28495AG00A) 

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 cutout portion facing the shaft end, since the cage has an orientation.
   Fig 1: Placing DOJ Boot At Center Of Shaft

   Courtesy of SUBARU OF AMERICA, INC.
4. Install the DOJ inner race on shaft and fix the snap ring in place with pliers.
   NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
   Fig 2: Fixing Snap Ring In Place With Pliers

   Courtesy of SUBARU OF AMERICA, INC.
5. Install the cage to inner race fixed upon shaft.
   NOTE: Fit the cage with the protruding section aligned with the track on the inner race, and turn by a half pitch.
   Fig 3: Identifying Inner Race And Cage

   Courtesy of SUBARU OF AMERICA, INC.
6. Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the inner side of the DOJ outer race.
7. Apply a thin coat of specified grease to the cage pocket and six ball bearings.
8. Insert the six ball bearings into the cage pocket.
9. Align the outer race track and ball positions, and place the shaft, inner race, cage and ball bearings in the original positions, and then fix outer race in place.
   Fig 4: Identifying Outer Race And Grease

   Courtesy of SUBARU OF AMERICA, INC.
10. Install the snap ring in the groove on the 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

      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 the 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 the DOJ boot, position the outer race of DOJ at center of the stroke.
13. Put a new band through the clip and wind twice in the band groove of the boot.
14. Pinch the end of band with pliers. Hold the clip and tighten securely.
    NOTE: When tightening boot, use care so that the air within the boot is appropriate.
15. Tighten the band using the ST.

    ST 925091000 BAND TIGHTENING TOOL

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

    Courtesy of SUBARU OF AMERICA, INC.
16. Tap the clip with the punch provided at the end of the ST.

    ST 925091000 BAND TIGHTENING TOOL

    NOTE: Tap to an extent that the boot underneath is not damaged.
    Fig 7: Tapping Clip With Punch

    Courtesy 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 a DOJ boot.
19. Extend and retract the DOJ repeatedly to provide an equal coating of grease.