Front Drive Shaft: Assembly

Roll up a thick sheet of paper, etc. to a size where the shaft can fit inside, and affix with tape to make a cylinder.
Attach a new O-ring on this cylinder.
CAUTION:
- Always use a new O-ring.
- Be careful that the O-ring does not become scratched and that there are no foreign objects attached to it.
- Make sure to install the O-ring so that it does not twist as much as possible.
- Do not stretch the O-ring to 30 mm (1.18 in) inner diameter or more.
Fig 1: Identifying Cylinder And O-Ring
Courtesy of SUBARU OF AMERICA, INC.
Pass the cylinder material onto the shaft, and slide in the direction of the shaft axis.

Fig 2: Identifying Cylinder Material, O-ring And Shaft
Courtesy of SUBARU OF AMERICA, INC.
Clean the shaft boot groove, and wipe off the grease.
Slide the cylinder material near the shaft boot groove, and move the O-ring from the cylinder material onto the shaft boot groove.

Fig 3: Identifying Cylinder Shaft Boot Groove
Courtesy of SUBARU OF AMERICA, INC.
CAUTION:
- Attach the O-ring to the shaft boot groove center.
- Be careful that the O-ring does not become scratched and that there are no foreign objects attached to it.
- Make sure to install the O-ring so that it does not twist as much as possible.
- With the O-ring attached, do not wash with kerosene, gasoline, etc.
Pass the PTJ small diameter boot band through the shaft.
Wrap vinyl tape around the splines of the shaft.
CAUTION: To prevent damage to the boots, make sure to always wrap with vinyl tape for protection.
Install a new PTJ boot.
CAUTION: Make sure to fit securely on the boot groove of the shaft.

Fig 4: Identifying PTJ Boot, O-ring And Boot Groove
Courtesy of SUBARU OF AMERICA, INC.
Match the alignment marks, and attach the trunnion onto the shaft.

Fig 5: Identifying Alignment Marks On Trunnion And Shaft
Courtesy of SUBARU OF AMERICA, INC.
Attach the snap ring to the shaft.
CAUTION: Confirm that the snap ring is completely fitted in the shaft groove.
Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of the PTJ outer race.
Grease:

NKG302
Apply a thin coat of specified grease to the roller kit and trunnion.
Match the alignment marks of the roller kit and trunnion, and attach the roller kit.
CAUTION: Be careful with the roller kit position.

Fig 6: Identifying Alignment Marks On Roller Kit And Trunnion
Courtesy of SUBARU OF AMERICA, INC.
Match the alignment marks of the shaft and outer race, and attach the outer race.

Fig 7: Identifying Alignment Marks On Shaft And Outer Race
Courtesy of SUBARU OF AMERICA, INC.
Install the snap ring in the groove of the PTJ outer race.
CAUTION: Pull the shaft lightly and make sure that the snap ring is completely fitted in the groove.
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.
Attach the PTJ boot taking care not to twist it.
CAUTION:
- Clean the larger end of PTJ boot and the boot groove well, and remove the grease and other substances.
- When installing the PTJ boot, position the outer race of the PTJ at center of the stroke.
Set the new boot band at the specified position.
Tighten the boot bands using ST, torque wrench and socket flex handle.
ST 28099AC000 BOOT BAND PLIER

CAUTION: The large boot band is to be tightened so that the omega shaped part is at the position indicated in the figure below.

Fig 8: Identifying Omega Shaped Part, Boot Band And Outer Race
Courtesy of SUBARU OF AMERICA, INC.

Fig 9: Identifying Large Boot Band, Torque Wrench And Socket Flex Handle
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

Large boot band

178 N.m (18.2 kgf-m, 131 ft-lb)

Small boot band

145 N.m (14.8 kgf-m, 107 ft-lb)
Extend and retract the PTJ repeatedly so that grease is spread evenly.