Front Drive Shaft: Assembly

AAR side: ONE LUBER (C) 

1. Pass the AAR boot through the shaft.
2. Match alignment marks and install the trunnion onto the shaft, and securely install the snap ring to the shaft groove.
   Fig 1: Identifying Alignment Marks On Trunnion And Shaft

   Courtesy of SUBARU OF AMERICA, INC.
3. Fill 50 to 60 g (1.76 to 2.12 oz) of specified grease into the inner side of the AAR outer race.
4. Apply a thin coat of specified grease to the roller and trunnion.
5. Place the drive shaft between wooden blocks etc, and secure it with a vise.
   CAUTION: Do not clamp the drive shaft directly with vise.
6. Match alignment marks of the shaft and outer race.
7. Tap the upper part of roller insertion on the outer race one after the other, using the plastic or wooden bar, to insert the roller one by one.
   CAUTION:

   • Do not use the metal rod because it may deform the outer race.
   • Do not tap the outer race tip (shaft part).
   • Be careful not to deform the baffle plate.
     Fig 2: Tapping Upper Part Of Roller Insertion On Outer Race

     Courtesy of SUBARU OF AMERICA, INC.
8. 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.
9. Install the AAR boot and grommet taking care not to twist them.
   Fig 3: Identifying Outer Race, Grommet And Boot

   Courtesy of SUBARU OF AMERICA, INC.
   CAUTION:

   • Replace the boot and grommet as a set.
   • Make sure the groove on the outer race side is free from grease.
10. Insert a flat tip screwdriver between the outer race and grommet so that the air pressure inside the boot is equal to the atmospheric pressure.
11. Install new large boot band and small boot band to the specified locations.
12. Tighten the boot band using ST, torque wrench and socket flex handle.

    ST 28099AC000 BOOT BAND PLIER

    Fig 4: Locating Boot Band And ST

    Courtesy of SUBARU OF AMERICA, INC.

    Clearance on the crimped section of boot band: 

    Large boot band 1 mm (0.04 in) or less 

    Small boot band 1 mm (0.04 in) or less 

13. Extend and retract the AAR repeatedly to provide an equal coating of grease.