Front Drive Shaft: Assembly

Pass the boot (OUT side) through the shaft assembly.
CAUTION: Be sure to wrap the shaft assembly splines with vinyl tape, etc. to protect the boot (OUT side) from scratches.
Apply 100 - 120g (3.5 - 4.2 oz) of grease into the interior of the boot (OUT side).
Preparation items:

Grease: NKG814 or the equivalent
Install the boot (OUT side).
CAUTION:
- Do not twist the boot (OUT side).
- Completely remove any grease that comes out and adheres to the outer surface of the boot (OUT side).
- Check that it fits in the boot groove securely.
Courtesy of SUBARU OF AMERICA, INC.
Set the new boot band (large) and new boot band (small).
Tighten the boot band (large) and boot band (small) using the ST.
CAUTION: The boot band (large) and boot band (small) are to be tightened so that the omega shaped part is at the position indicated in the figure.

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

Boot band (large)

178 N.m (18.2 kgf-m, 131.3 ft-lb)

Boot band (small)

145 N.m (14.8 kgf-m, 106.9 ft-lb)

Preparation tool:

ST: BOOT BAND PLIER (28099AC000)

Courtesy of SUBARU OF AMERICA, INC.
Extend and retract the boot (OUT side) repeatedly so that grease is spread evenly.
Pass the boot band (small), boot (IN side) and snap ring through the shaft assembly.
CAUTION: Be sure to wrap the shaft assembly splines with vinyl tape, etc. to protect the boot (IN side) from scratches.

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Roll up a thick piece of paper to a size where the shaft assembly can pass through, and affix with tape to form a cylinder.
Set a new O-ring on this cylinder.
CAUTION:
- Be careful not to damage the O-ring.
- Make sure to install the O-ring so that it does not twist.
- Do not stretch the O-ring to 30 mm (1.2 in) or more in an inner diameter.
Courtesy of SUBARU OF AMERICA, INC.
Pass the cylinder material through the shaft assembly.

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Slide the cylinder material to the shaft assembly boot groove, and move the O-ring from the cylinder material onto the shaft assembly boot groove.
CAUTION:
- Attach the O-ring to the shaft assembly boot groove center.
- Make sure to install the O-ring so that it does not twist.
- Check that the O-ring does not become scratched and that there are no foreign objects attached to it.
Courtesy of SUBARU OF AMERICA, INC.
Remove the cylinder material.
Align alignment marks, set the trunnion and install the snap ring.
CAUTION: Pull the shaft assembly lightly and assure that the snap ring is completely fitted.

Courtesy of SUBARU OF AMERICA, INC.
Apply 100 - 110 g (3.5 - 3.9 oz) of grease into the interior of outer race.
Preparation items:

Grease: NKG302 or the equivalent
Apply a thin coat of grease to the bearing and trunnion bearing installation portion.
Preparation items:

Grease: NKG302 or the equivalent
Align alignment marks, and install the bearing.

Courtesy of SUBARU OF AMERICA, INC.
Align alignment marks, set the outer race and install the snap ring.
CAUTION: Pull the shaft assembly lightly and assure that the snap ring is completely fitted.

Courtesy of SUBARU OF AMERICA, INC.
Apply 45 - 50 g (1.6 - 1.8 oz) of grease evenly to the entire inner surface of boot (IN side).
Preparation items:

Grease: NKG302 or the equivalent
Install the boot (IN side).
CAUTION:
- Do not twist the boot (IN side).
- Completely remove any grease that comes out and adheres to the outer surface of the boot (IN side).
- Check that it fits in the boot groove securely.
Courtesy of SUBARU OF AMERICA, INC.
Set the new boot band (large) and new boot band (small).
Tighten the boot band (large) and boot band (small) using the ST.
CAUTION: The boot band (large) and boot band (small) are to be tightened so that the omega shaped part is at the position indicated in the figure.

Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

Boot band (large)

178 N.m (18.2 kgf-m, 131.3 ft-lb)

Boot band (small)

145 N.m (14.8 kgf-m, 106.9 ft-lb)

Preparation tool:

ST: BOOT BAND PLIER (28099AC000)

Courtesy of SUBARU OF AMERICA, INC.
Extend and retract the boot (IN side) repeatedly so that grease is spread evenly.