Front Drive Shaft: Disassembly

WARNING: This page is about a different car, the 2012 Subaru Outback and 2012 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.

Remove the AAR outer race from shaft assembly.
CAUTION: Be careful not to damage the boot.
1. Place alignment marks on the shaft and outer race.
  
  Fig 1: Identifying Alignment Marks On Shaft And Outer Race
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the AAR boot band and boot.
  
  Fig 2: Removing AAR Boot Band And Boot
  Courtesy of SUBARU OF AMERICA, INC.
3. Place the drive shaft between wooden blocks and fix it on a vise.
  CAUTION: Do not set the only drive shaft on a vise.
  
  Fig 3: Placing Drive Shaft Between Wooden Blocks And Fix On Vise
  Courtesy of SUBARU OF AMERICA, INC.
4. Tap the staking are of the outer race alternately with a plastic or wooden bar, and remove one roller at a time.
  CAUTION:
  - Tap the staking area (A) of the outer race.
  - Do not use a metal bar as the outer race may deform.
  - Be careful not to damage the roller parts.
  Fig 4: Tapping Staking Area Of Outer Race
  Courtesy of SUBARU OF AMERICA, INC.
5. Remove the outer race from shaft assembly.
  CAUTION: Make sure to have your associate held the outer race when removing the third roller to prevent the outer race from falling.
6. Wipe off grease.
  CAUTION: The grease is a special type of grease. Do not mix with other grease.
Remove the roller kit from trunnion.
CAUTION: Be careful with the roller kit position.
1. Place alignment marks on the roller kit and trunnion.
  
  Fig 5: Placing Alignment Marks On Roller Kit
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the roller kit from trunnion.
Remove the trunnion from the shaft.
1. Place alignment marks on the trunnion and shaft.
2. Remove the snap ring and trunnion.
CAUTION: Be sure to wrap shaft splines with vinyl tape to protect the boot from scratches.

Fig 6: Identifying Alignment Marks On Trunnion And Shaft
Courtesy of SUBARU OF AMERICA, INC.
Remove the AAR boot.
NOTE: The AC is a non-disassembly part, so the drive shaft disassembly stops here.