Front Drive Shaft: Assembly

BJ side (Non-TURBO model, outside): 

NTG2218-M (Part No. 28395AG030) 

SFJ side (Non-TURBO model, inside): 

NKG302 (Part No. 28495AE010) 

AC side (TURBO model, outside): 

HTBJ (Part No. 28395SA010) 

AAR side (TURBO model, inside): 

One luber C (Part No. 28395SA000) 

1. Place outer joint boot and small boot band on outer joint side of shaft.
   CAUTION: Be careful not to damaged boot by wrapping shaft splines with vinyl tape.
2. Place drive shaft in a vise.
   CAUTION: Do not place drive shaft directly in the vise; use wooden blocks.
3. Apply a coat of specified grease [60 to 70 g (2.12 to 2.47 oz)] to outer joint.
4. Apply an even coat of specified grease [20 to 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply grease to shaft.
   NOTE: The inside of the larger end of outer joint boot and the boot groove shall be cleaned so as to be free from grease and other substances.
5. Install boot projecting portion to outer joint groove.
   Fig 1: Installing Boot Projecting Portion To Outer Joint Groove

   Courtesy of SUBARU OF AMERICA, INC.
6. Set large boot band in place.
7. Install boot projecting portion to shaft groove.
   Fig 2: Installing Boot Projecting Portion To Shaft Groove

   Courtesy of SUBARU OF AMERICA, INC.
8. Tighten boot bands using ST, torque wrench and socket flex handle.

   ST 28099AC000 BOOT BAND PLIER

   Fig 3: Locating Boot Bands

   Courtesy of SUBARU OF AMERICA, INC.

   Tightening torque: 

   Large boot band 

   157 N.m (16.0 kgf-m, 116 ft-lb) or more 

   Small boot band 

   133 N.m (13.6 kgf-m, 98 ft-lb) or more 

9. Place inner joint boot at the center of shaft.
10. Align alignment marks and install trunnion on shaft.
    Fig 4: Installing Trunnion On Shaft

    Courtesy of SUBARU OF AMERICA, INC.
11. Install snap ring to shaft.
    CAUTION: Confirm that the snap ring is completely fitted in the shaft groove.
12. Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of inner joint outer race.
13. Apply a coat of specified grease to free ring and trunnion.
14. Align alignment marks on free ring and trunnion and install free ring.
    CAUTION: Be careful with the free ring position.
    Fig 5: Aligning Alignment Marks On Free Ring And Trunnion

    Courtesy of SUBARU OF AMERICA, INC.
15. Align alignment marks on shaft and outer race, and install outer race.
    Fig 6: Aligning Alignment Marks On Shaft And Outer Race

    Courtesy of SUBARU OF AMERICA, INC.
16. Install circlip in the groove on inner joint outer race.
    CAUTION: Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
17. 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.
18. Install inner joint boot taking care not to twist it.
    CAUTION:

    • The inside of the larger end of inner joint boot and the boot groove shall be cleaned so as to be free from grease and other substances.
    • When installing inner joint boot, position outer race of inner joint at center of its travel.
19. Put a band through the clip and wind twice in alignment with band groove of boot.
    CAUTION: Replace the removed boot band with a new one.
20. Tighten band by using ST.

    ST 925091000 BAND TIGHTENING TOOL

    NOTE: Tighten band until it cannot be moved by hand.
    Fig 7: Locating Band

    Courtesy of SUBARU OF AMERICA, INC.
21. 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.
    Fig 8: Taping On Clip With Punch

    Courtesy of SUBARU OF AMERICA, INC.
22. 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: Bend the band so that its end is in close contact with clip.
23. Fix up boot on outer joint in the same manner.
24. Extend and retract inner joint to provide equal grease coating.