1999 SUBARU LEGACY Service Repair Manual

CAUTION:
Be careful not to damage side bearing retainer.
Always use bolt as shown in figure, as support-
ing point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0995
10) Remove DOJ from rear differential using tire
lever. (2200 cc AT vehicles)
NOTE:
The side spline shaft circlip comes out together
with the shaft.
G3M0257
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the axle shaft
holder.
G3M0045
11) Remove axle nut and drive shaft. If it is hard
to remove, use ST1 and ST2.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
IBe careful not to damage oil seal lip when
removing rear drive shaft.
IWhen rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
G4M0247
B: DISASSEMBLY
1. EXCEPT AWD AT FRONT DRIVE SHAFT
1) Remove both DOJ boot bands.
2) Loosen band by means of screwdriver or pliers
taking care to not damage the boot.
G4M0281
3) Remove the larger end of DOJ boot from DOJ
outer race.
4) Pry and remove round circlip located at the
neck of DOJ outer race with a screwdriver.
G4M0282
23
[W3B1]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

5) Take out DOJ outer race from shaft assembly.
6) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for con-
stant velocity joint). Do not confuse with other
greases.
NOTE:
Disassemble exercising care not to lose balls (6
pcs).
B4M0227C
NOTE:
Clean all parts as necessary.
7) To remove the cage from the inner race, turn
the cage by a half pitch to the track groove of the
inner race and shift the cage.
8) Remove snap ring, which holds the inner race
to shaft, by using pliers.
9) Take out DOJ inner race.
10) Take off DOJ cage from shaft and remove
DOJ boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
protect the boot from scratches.
11) Place drive shaft in a vise between wooden
blocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.12) Raise boot band claws by means of screw-
driver and hammer.
B4M0689A
13) Cut and remove the boot.
CAUTION:
The boot must be replaced with a new one
whenever it is removed.
B4M0690
14) Thus, disassembly of axle is completed, but
BJ cannot be disassembled.
24
4-2[W3B1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

2. AWD AT FRONT DRIVE SHAFT
1) Place alignment marks on shaft and outer race.
B4M0774
2) Remove SFJ boot band and boot.
CAUTION:
Be careful not to damage boot.
B4M0775A
3) Remove circlip from SFJ outer race using
screwdriver.
B4M0776
4) Remove SFJ outer race from shaft assembly.
5) Wipe off grease.
CAUTION:
The grease is a special grease. Do not confuse
with other greases.6) Place alignment mark on free ring and trunnion.
B4M0777
7) Remove free ring from trunnion.
8) Place alignment mark on trunnion and shaft.
B4M0778
9) Remove snap ring and trunnion.
B4M0779
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
10) Remove SFJ boot.
25
[W3B2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

11) Place drive shaft in a vise between wooden
blocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.
12) Raise boot band claws by means of screw-
driver and hammer.
B4M0689A
13) Cut and remove the boot.
CAUTION:
The boot must be replaced with a new one
whenever it is removed.
B4M0690
14) Thus, disassembly of axle is completed, but
BJ cannot be disassembled.
3. REAR DRIVE SHAFT
1) Straighten bent claw of larger end of DOJ boot.2) Loosen band by means of screwdriver or pliers
with care of not damaging boot.
G4M0281
3) Remove boot band on the small end of DOJ
boot in the same manner.
4) Remove the larger end of DOJ boot from DOJ
outer race.
5) Pry and remove round circlip located at the
neck of DOJ outer race with a screwdriver.
G4M0282
6) Take out DOJ outer race from shaft assembly.
7) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for con-
stant velocity joint). Do not confuse with other
greases.
NOTE:
Disassemble exercising care not to lose balls (6
pcs).
B4M0227C
8) To remove the cage from the inner race, turn
the cage by a half pitch to the track groove of the
inner race and shift the cage.
26
4-2[W3B3]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

9) Remove snap ring, which fixes inner race to
shaft, by using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ
boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
12) Remove BJ boot in the same procedure as
DOJ boot.
13) Thus, disassembly of axle is completed, but
BJ is unable to be disassembled.
C: INSPECTION
Check the removed parts for damage, wear, corro-
sion etc. If faulty, repair or replace.
1) DOJ (Double Offset Joint)
Check seizure, corrosion, damage, wear and
excessive play.
2) SFJ (Shudder-less Freering tripod Joint)
Check seizure, corrosion, damage and excessive
play.
3) Shaft
Check excessive bending, twisting, damage and
wear.
4) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.
D: ASSEMBLY
1. EXCEPT AWD AT FRONT DRIVE SHAFT
CAUTION:
Use specified grease.
BJ side:
NTG2218 (Part No. 28093AA020)
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
1) Place BJ boot and small boot band on BJ side
of shaft.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
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 BJ.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 BJ boot and the boot
groove shall be cleaned so as to be free from
grease and other substances.
5) Install boot projecting portion to BJ groove.
B4M1296A
6) Set large boot band in place.
7) Install boot projecting portion to shaft groove.
B4M1297A
8) Tighten boot bands using ST, torque wrench
and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
B4M0693B
(1) Large boot band
(2) Boot
(3) Torque wrench
(4) Socket flex handle
(5) BJ
27
[W3D1]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

Tightening torque:
Large boot band
157 N´m (16.0 kg-m, 116 ft-lb) or more
Small boot band
133 N´m (13.6 kg-m, 98 ft-lb) or more
9) Place DOJ boot at the center of shaft.
10) Insert DOJ cage onto shaft.
NOTE:
Insert the cage with the cut-out portion facing the
shaft end, since the cage is directional.
G4M0284
11) Install DOJ inner race on shaft and fit snap
ring with pliers.
NOTE:
Confirm that the snap ring is completely fitted in the
shaft groove.
G4M0285
12) Install cage, which was previously fitted, to
inner race fixed upon shaft.
NOTE:
Fit the cage with the protruded part aligned with the
track on the inner race and then turn by a half
pitch.
B4M0228C
13) Put 80 to 90 g (2.82 to 3.17 oz) of specified
grease into the interior of DOJ outer race.
14) Apply a coat of specified grease to the cage
pocket and six balls.
15) Insert six balls into the cage pocket.
16) Align the outer race track and ball positions
and place in the part where shaft, inner race, cage
and balls are previously installed, and then fit outer
race.
B4M0227C
28
4-2[W3D1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

17) Install circlip in the groove on DOJ outer race.
NOTE:
IAssure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
IExercise care not to match the open end of cir-
clip in the ball groove of outer race.
IPull the shaft lightly and assure that the circlip is
completely fitted in the groove.
G4M0282
18) 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.
19) Install DOJ boot taking care not to twist it.
NOTE:
IThe inside of the larger end of DOJ boot and the
boot groove shall be cleaned so as to be free from
grease and other substances.
IWhen installing DOJ boot, position outer race of
DOJ at center of its travel.
20) Put a band through the clip and wind twice in
alignment with band groove of boot.
CAUTION:
Use a new band.
21) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening boot, exercise care so that the air
within the boot is appropriate.22) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0289
23) Tap on the clip with the punch provided at the
end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap only to the extent that the boot underneath
is not damaged.
G4M0290
24) Cut off band with an allowance of about 10
mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
CAUTION:
Be careful so that the end of the band is in
close contact with clip.
25) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coating.
2. AWD AT FRONT DRIVE SHAFT
CAUTION:
Use specified grease.
BJ side:
NTG2218 (Part No. 28093AA020)
SFJ side:
NTG30B (Part No. 28095AC000)
1) Place BJ boot and small boot band on BJ side
of shaft.
29
[W3D2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
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 BJ.
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 BJ boot and the boot
groove shall be cleaned so as to be free from
grease and other substances.
5) Install boot projecting portion to BJ groove.
B4M1296A
6) Set large boot band in place.
7) Install boot projecting portion to shaft groove.
B4M1297A
8) Tighten boot bands using ST, torque wrench
and socket flex handle.
ST 28099AC000 BOOT BAND PLIER
B4M0693B
(1) Large boot band
(2) Boot
(3) Torque wrench
(4) Socket flex handle
(5) BJ
Tightening torque:
Large boot band
157 N´m (16.0 kg-m, 116 ft-lb) or more
Small boot band
133 N´m (13.6 kg-m, 98 ft-lb) or more
9) Place SFJ boot at the center of shaft.
10) Align alignment marks and install trunnion on
shaft.
B4M0778
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 SFJ outer race.
13) Apply a coat of specified grease to free ring
and trunnion.
30
4-2[W3D2]SERVICE PROCEDURE
3. Front and Rear Drive Shafts