Front Drive Shaft: Assembly

AAR side: 

ONE LUBER C (Part No. 28395SA020) 

1. Pass the AAR boot through the shaft.
2. Align alignment marks and install the trunnion on the shaft. Install the snap ring into the shaft groove securely.
   Fig 1: Aligning Alignment Marks

   Courtesy of SUBARU OF AMERICA, INC.
3. Fill 50 to 60 g (1.76 to 2.12 oz) of specified grease into the interior of AAR outer race.
4. Apply a thin coat of specified grease to the roller and trunnion.
5. Place the drive shaft between wooden blocks and fix it on a vise.
   CAUTION: Do not fix the drive shaft on a vise directly.
6. Align the alignment marks on the shaft and outer race.
7. Tap the area of the outer race where rollers are inserted alternately with a plastic or wooden bar to insert one roller at a time as shown in the figure.
   CAUTION:

   • Do not use a metal bar as the outer race may deform.
   • Do not tap on the end of outer race (shaft part).
   • Be careful not to deform the baffle plate.
   Fig 2: Tapping Area Of Outer Race Where Rollers

   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 taking care not to twist it.
10. Install the new large boot band and small boot band at the required positions.
11. Tighten the boot bands using ST, torque wrench and socket flex handle.

    ST 28099AC000 BOOT BAND PLIER

    Fig 3: Identifying Large Boot Band, Boot, Torque Wrench And Socket Flex Handle

    Courtesy of SUBARU OF AMERICA, INC.

    Clearance at the crimped section of the boot band: 

    Large boot band 

    1 mm (0.04 in) or less 

    Small boot band 

    1 mm (0.04 in) or less 

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