Rear Drive Shaft: Assembly

DOJ side: 

NKG205 

1. Place the DOJ boot at the center of shaft.
   CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches.
2. Insert the DOJ cage onto shaft.
   NOTE: Insert the cage with the cutout portion facing the shaft end, since the cage has an orientation.
   Fig 1: Identifying Cage And Cutout Portion

   Courtesy of SUBARU OF AMERICA, INC.
3. Install the DOJ 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.
   Fig 2: Removing/Installing Snap Ring

   Courtesy of SUBARU OF AMERICA, INC.
4. 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.
   Fig 3: Identifying Cage And Inner Race

   Courtesy of SUBARU OF AMERICA, INC.
5. Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the inner side of the DOJ outer race.
6. Apply a thin coat of specified grease to the cage pocket and six ball bearings.
7. Insert the six ball bearings into the cage pocket.
8. 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: Identifying Ball Bearing Grease Area

   Courtesy of SUBARU OF AMERICA, INC.
9. Install the snap ring in the groove on the DOJ outer race.
   NOTE:

   • Assure 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.
     Fig 5: Removing/Installing Circlip In Groove Of DOJ Outer Race

     Courtesy of SUBARU OF AMERICA, INC.
10. 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.
11. 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.
12. Put a new band through the clip and wind twice in the band groove of the boot.
13. 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.
14. Tighten the band using the ST.

    ST 925091000 BAND TIGHTENING TOOL

    NOTE: Tighten the band until it cannot be moved by hand.
    Fig 6: Locating Band And ST 925091000 Band Tool

    Courtesy of SUBARU OF AMERICA, INC.
15. 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.
    Fig 7: Tapping Clip Using ST 925091000 Band Tool

    Courtesy of SUBARU OF AMERICA, INC.
16. 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.
    NOTE: Be careful so that the end of the band is in close contact with clip.
17. Install the EBJ boot using the same procedures as for the DOJ boot.
18. Extend and retract the DOJ repeatedly to provide an equal coating of grease.