Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 516

DS-37

Rear Drive Shaft

DRIVE SHAFT SYSTEM

C: DISASSEMBLY

1. EXCEPT FOR STI MODEL

1) Using a flat tip screwdriver or plier, loosen the

boot band on the large end of DOJ boot.
CAUTION:

Be careful not to damage the boot.

2) Remove the boot band on the small end of DOJ

boot in the same manner.

3) Remove the large end of DOJ boot from DOJ

outer race.

4) Remove the round snap ring at the neck of DOJ

outer race with a flat tip screwdriver.

5) Take out the DOJ outer race from the shaft as-

sembly.

6) Wipe off the grease and take out the ball bear-

ings.
CAUTION:

The grease is a special grease (grease for con-

stant velocity joints). Do not mix with other

greases.
NOTE:

Disassemble exercising care not to lose balls.

7) To remove the cage from inner race, turn the

cage by a half pitch to the track groove of inner race

and shift the cage.

8) Using pliers, remove the snap ring fixing the in-

ner race to the shaft.

9) Take out the DOJ inner race.

10) Take off the DOJ cage from shaft and remove

the DOJ boot.
CAUTION:

Wrap shaft splines with vinyl tape to protect the

boot from scratches.

11) Remove the EBJ boot using the same proce-

dures as for the DOJ boot.
NOTE:

The EBJ is a non-disassembly part, so the drive

shaft disassembly stops here.

DS-00124

DS-00125

(A) Outer race
(B) Grease

DS-00126

(B)

(A)

DS-38

Rear Drive Shaft

DRIVE SHAFT SYSTEM

2. STI MODEL

1) Using a flat tip screwdriver or plier, loosen the

boot band on the large end of EDJ boot.
CAUTION:

Be careful not to damage the boot.

2) Remove the boot band on the small end of EDJ

boot in the same manner.

3) Remove the large end of EDJ boot from EDJ

outer race.

4) Remove the round snap ring at the neck of EDJ

outer race with a flat tip screwdriver.

5) Remove the EDJ outer race from shaft assem-

bly.

6) Wipe off the grease and take out the ball bear-

ings.
CAUTION:

The grease is a special grease (grease for con-

stant velocity joints). Do not mix with other

greases.
NOTE:

Disassemble exercising care not to lose balls.

7) To remove the cage from inner race, turn the

cage by a half pitch to the track groove of inner race

and shift the cage.

8) Using pliers, remove the snap ring fixing the in-

ner race to the shaft.

9) Take out the EDJ inner race.

10) Take off the EDJ cage from shaft and remove

the EDJ boot.
CAUTION:

Wrap shaft splines with vinyl tape to protect the

boot from scratches.

11) Remove the EBJ boot using the same proce-

dures as for the EDJ boot.
NOTE:

The EBJ is a non-disassembly part, so the drive

shaft disassembly stops here.

DS-00124

DS-00125

(A) Outer race
(B) Grease

DS-00126

(B)

(A)

DS-39

Rear Drive Shaft

DRIVE SHAFT SYSTEM

D: ASSEMBLY

1. STI MODEL

CAUTION:

Wrap shaft splines with vinyl tape to protect the

boot from scratches.
NOTE:

Use specified grease.
EBJ side:

NKG814

EDJ side:

NKG814

1) Install the EBJ boot to the specified position, and

fill it with 50 to 60 g (1.76 to 2.12 oz) of specified

grease.

2) Place the EDJ boot at the center of shaft.

3) Insert the EDJ cage onto shaft.
NOTE:

Insert the cage with the cutout portion facing the

shaft end, since the cage has an orientation.

4) Install the EDJ 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.

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.

6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified

grease into the inner side of the EDJ outer race.

7) Apply a thin coat of specified grease to the cage

pocket and ball.

8) Insert the 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.

(A) Cage
(B) Cutout portion

DS-00395

(B)

(A)

DS-00128

(A) Inner race
(B) Cage

(A) Outer race
(B) Grease

DS-00129

(B)

(A)

DS-00126

(B)

(A)

DS-40

Rear Drive Shaft

DRIVE SHAFT SYSTEM

10) Install the snap ring in the groove on the EDJ

outer race.
NOTE:

• Assure that the balls, cage and inner race are

completely fitted in the outer race of EDJ.

• 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.

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 EDJ boot taking care not to twist it.
NOTE:

• The inside of the large end of EDJ boot and the

boot groove shall be cleaned so as to be free from

grease and other substances.

• When installing the EDJ boot, position the outer

race of EDJ 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 with-

in 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.

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.

17) Cut off the band with an allowance of about 10

mm (0.39 in) left from the clip and bend this allow-

ance over the clip.
NOTE:

Be careful so that the end of the band is in close

contact with clip.

18) Install the EBJ boot using the same procedures

as for the EDJ boot.

19) Extend and retract the EDJ repeatedly to pro-

vide an equal coating of grease.

DS-00125

DS-00132

DS-00133