Subaru Legacy III (2000-2003 year). Manual — part 689

DS-34

DRIVE SHAFT SYSTEM

REAR DRIVE SHAFT

6. Rear Drive Shaft

A: REMOVAL

1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.

CAUTION:
Be sure to loosen and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
5) Remove rear differential assembly.
With T-type
<Ref. to DI-24, REMOVAL, Rear Differential for T-
type.>
With VA-type
<Ref. to DI-41, REMOVAL, Rear Differential for
VA-type.>
6) Remove axle nut and drive shaft. If it is hard to
remove, use ST1 and ST2.
ST1

926470000

AXLE SHAFT PULLER

ST2

927140000

PLATE

CAUTION:
Be careful not to damage tone wheel when re-
moving rear drive shaft.

B: INSTALLATION

1) Insert BJ into rear hub splines.

CAUTION:
Be careful not to damage tone wheel.
2) Using ST1 and ST2, pull drive shaft into place.
ST1

922431000

AXLE SHAFT INSTALLER

ST2

927390000

ADAPTER

CAUTION:
Do not hammer drive shaft when installing it.

3) Tighten axle nut temporarily.
4) Install rear differential.
With T-type
<Ref. to DI-25, INSTALLATION, Rear Differential
for T-type.>
With VA-type
<Ref. to DI-42, INSTALLATION, Rear Differential
for VA-type.>
5) While depressing brake pedal, tighten axle nut
using a socket wrench.

Tightening torque:

186 N·m (19 kgf-m, 137 ft-lb)

CAUTION:
• Use a new axle nut for rear use only (Olive
color).
• Always tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
• Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
6) After tightening axle nut, lock it securely.

DS-00122

ST1

ST2

ST

DS-00123

DS-35

DRIVE SHAFT SYSTEM

REAR DRIVE SHAFT

C: DISASSEMBLY

1) Straighten bent claw of larger end of DOJ boot.
2) Loosen band by means of screwdriver or pliers,
being careful not to damage the boot.

3) Remove boot band on the small end of DOJ boot
in the same manner.
4) Remove the larger end of DOJ boot from DOJ
outer race.
5) Pry and remove round circlip located at the neck
of DOJ outer race with a screwdriver.

6) Take out DOJ outer race from shaft assembly.

7) Wipe off grease and take out balls.

CAUTION:
The grease is a special grease (grease for con-
stant velocity joint). Do not confuse with other
greases.

NOTE:
Disassemble exercising care not to lose balls (6
pcs).

8) To remove the cage from the inner race, turn the
cage by a half pitch to the track groove of the inner
race and shift the cage.
9) Remove snap ring, which fixes inner race to
shaft, by using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ
boot.

CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
12) Remove BJ boot in the same procedure as
DOJ boot.
13) Disassembly of axle is completed at steps
above because BJ cannot be disassembled.

DS-00124

DS-00125

(A) Outer race

(B) Grease

DS-00126

( A )

( B )

DS-36

DRIVE SHAFT SYSTEM

REAR DRIVE SHAFT

D: ASSEMBLY

CAUTION:
Use specified grease.

BJ side:

Molylex No. 2 (Part No. 723223010)

DOJ side:

VU-3A702 (Yellow) (Part No. 23223GA050)

1) Install BJ boot in specified position, and fill it with
60 to 70 g (2.12 to 2.47 oz) of specified grease.
2) Place DOJ boot at the center of shaft.

CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
3) Insert DOJ cage onto shaft.

NOTE:
Insert the cage with the cut-out portion facing the
shaft end, since the cage has an orientation.

4) Install DOJ inner race on shaft and fit snap ring
with pliers.

NOTE:
Confirm that the snap ring is completely fitted in the
shaft groove.

5) Install cage, which was previously fitted, to inner
race fixed upon shaft.

NOTE:
Fit the cage with the protruded part aligned with the
track on the inner race and then turn by a half pitch.

6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
grease into the interior of DOJ outer race.
7) Apply a coat of specified grease to the cage
pocket and six balls.
8) Insert six balls into the cage pocket.
9) Align the outer race track and ball positions and
place in the part where shaft, inner race, cage and
balls are previously installed, and then fit outer
race.

(A) Cage

(B) Cut-out portion

DS-00127

( A )

( B )

DS-00128

(A) Inner race

(B) Cage

(A) Outer race

(B) Grease

DS-00129

( A )

( B )

DS-00126

( A )

( B )

DS-37

DRIVE SHAFT SYSTEM

REAR DRIVE SHAFT

10) Install circlip in the groove on DOJ outer race.

NOTE:
• Assure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
• Exercise care not to place the matched position
of circlip 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 shaft.
12) Install 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 DOJ boot, position outer race of
DOJ at center of its travel.
13) Put a band through the clip and wind twice in
alignment with band groove of boot.

CAUTION:
Use a new band.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely.

NOTE:
When tightening boot, exercise care so that the air
within the boot is appropriate.
15) Tighten band by using ST.
ST

925091000

BAND TIGHTENING TOOL

NOTE:
Tighten band until it cannot be moved by hand.

16) Tap on the clip with the punch provided at the
end of ST.
ST

925091000

BAND TIGHTENING TOOL

CAUTION:
Tap to an extent that the boot underneath is not
damaged.

17) Cut off band with an allowance of about 10 mm
(0.39 in) left from the clip and bend this allowance
over the clip.

CAUTION:
Be careful so that the end of the band is in close
contact with clip.
18) Fix up boot on BJ in the same manner.

NOTE:
Extend and retract DOJ to provide equal grease
coating.

E: INSPECTION

Check the removed parts for damage, wear, corro-
sion etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and ex-
cessive play.
2) SFJ (Shudder-less Free-ring tripod Joint)
Check seizure, corrosion, damage and excessive
play.
3) Shaft
Check excessive bending, twisting, damage and
wear.
4) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.

DS-00125

DS-00132

DS-00133