Rear Drive Shaft: Assembly

BJ, EBJ side: 

NKG106 

DOJ side: 

NKG205 

1. Install the DOJ inner race to the shaft.
   1. Install the BJ or EBJ boot in specified position, and fill it with 50 to 60 g (1.76 to 2.12 oz.) of specified grease.
   2. Place the DOJ boot at the center of shaft.
   3. Insert the DOJ cage onto shaft.
   Fig 1: Inserting DOJ Cage Onto Shaft

   Courtesy of SUBARU OF AMERICA, INC.
   NOTE: Insert the cage with the cutout portion facing the shaft end, since the cage has an orientation.
2. Install the DOJ inner race on shaft and fix the snap ring in place with pliers.
   Fig 2: Installing DOJ Inner Race On Shaft And Snap Ring

   Courtesy of SUBARU OF AMERICA, INC.
   NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
3. Install the cage to the inner race.
   1. Install the cage (B) with the protruding section aligned with the track on the inner race (A), and turn by a half pitch.
      Fig 3: Installing Cage With Protruding Section On Inner Race

      Courtesy of SUBARU OF AMERICA, INC.
   2. Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the inner side of the DOJ outer race.
   3. Apply a thin coat of specified grease to the cage pocket and ball.
   4. Insert the ball bearings into the cage pocket.
   5. Connect the shaft assembly to the outer race.
      1. 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: Connecting Shaft Assembly To Outer Race

         Courtesy of SUBARU OF AMERICA, INC.
      2. Install the snap ring in the groove on the DOJ outer race.
         CAUTION: Be careful of the following items during installation:

         • Make sure 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.
      3. 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.
      4. Install the DOJ boot taking care not to twist it.
         NOTE:

         • The inside of the large 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.
      5. Put a new band through the clip and wind twice in the band groove of the boot.
      6. 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.
      7. Tighten the band using the ST.

         PREPARATION TOOL: 

         ST: BAND TIGHTENING TOOL (925091000) 

         Fig 5: Locating Band And ST

         Courtesy of SUBARU OF AMERICA, INC.
         NOTE: Tighten the band until it cannot be moved by hand.
      8. Tap the clip with the punch provided at the end of the ST.

      PREPARATION TOOL: 

      ST: BAND TIGHTENING TOOL (925091000) 

      Fig 6: Tapping Clip With Punch At End Of ST

      Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Tap to an extent that the boot underneath is not damaged.
   6. 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.
      CAUTION: Make sure that the end of the band is in close contact with clip.
4. Install the BJ boot or EBJ boot in the same procedure as a DOJ boot.
5. Extend and retract the DOJ repeatedly to provide an equal coating of grease.