1999 SUBARU LEGACY Service Repair Manual

14) Align alignment marks on free ring and trun-
nion and install free ring.
B4M0777
15) Align alignment marks on shaft and outer
race, and install outer race.
B4M0774
16) Install circlip in the groove on SFJ 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 SFJ boot taking care not to twist it.
CAUTION:
IThe inside of the larger end of SFJ boot and
the boot groove shall be cleaned so as to be
free from grease and other substances.
IWhen installing SFJ boot, position outer
race of SFJ at center of its travel.
19) Put a band through the clip and wind twice in
alignment with band groove of boot.CAUTION:
Use a new band.
20) 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.
21) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0289
22) 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.
G4M0290
23) 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.
24) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract SFJ to provide equal grease
coating.
31
[W3D2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

3. REAR DRIVE SHAFT
CAUTION:
Use specified grease.
BJ side:
Molylex No. 2 (Part No. 723223010) or
Sunlight TB2-A
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
1) Install BJ boot in specified position, and fill it
with 60 to 70 g (2.12 to 2.47 oz) of specified
grease.
2) Place DOJ boot at the center of shaft.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
3) Insert DOJ cage onto shaft.
NOTE:
Insert the cage with the cut-out portion facing the
shaft end, since the cage has an orientation.
G4M0284
4) 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
5) 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
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
grease into the interior of DOJ outer race.
7) Apply a coat of specified grease to the cage
pocket and six balls.
8) Insert six balls into the cage pocket.
9) 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
32
4-2[W3D3]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

10) 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 place the matched position
of circlip in the ball groove of outer race.
IPull the shaft lightly and assure that the circlip is
completely fitted in the groove.
G4M0282
11) 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 shaft.
12) 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.
13) Put a band through the clip and wind twice in
alignment with band groove of boot.
CAUTION:
Use a new band.
14) 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.15) Tighten band by using ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten band until it cannot be moved by hand.
G4M0289
16) 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.
G4M0290
17) 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.
18) Fix up boot on BJ in the same manner.
NOTE:
Extend and retract DOJ to provide equal grease
coating.
33
[W3D3]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

E: INSTALLATION
1. FRONT DRIVE SHAFT
1) Insert BJ into hub splines.
CAUTION:
Be careful not to damage inner oil seal lip.
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
G4M0291
3) Tighten axle nut temporarily.
4) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
5) Connect transverse link to housing.
Tightening torque (self-locking nut):
49
±10 N´m (5.0±1.0 kg-m, 36±7 ft-lb)
CAUTION:
Use a new self-locking nut.
6) Install stabilizer bracket.
7) While depressing brake pedal, tighten axle nut
to the specified torque.
Tightening torque:
186
±20 N´m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
IUse a new axle nut.
IAlways tighten axle nut before installing
wheel on vehicle. If wheel is installed andcomes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
IBe sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
8) After tightening axle nut, lock it securely.
2. REAR DRIVE SHAFT
1) Insert BJ into rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
G4M0293
3) Tighten axle nut temporarily.
4) Replace circlips from DOJ spline with new one.
(2200 cc AT vehicles only)
5) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0549A
34
4-2[W3E1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

6) Insert DOJ spline end into bore of side oil seal,
and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0550A
7) Align DOJ and differential splines.
8) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
9) Connect crossmember reinforcement lower to
crossmember (4 door model only).
10) Connect rear housing assembly to trailing link
assembly, and tighten self-locking nut.
Tightening torque:
11 3
±15 N´m (11.5±1.5 kg-m, 83±11 ft-lb)
11) Connect rear housing assembly to lateral link
assembly, and tighten self-locking nut.
Tightening torque:
137
±20 N´m (14±2 kg-m, 101±14 ft-lb)
12) Install stabilizer bracket.
13) While depressing brake pedal, tighten axle nut
using a socket wrench.
Tightening torque:
186
±20 N´m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
IUse a new axle nut.
IAlways tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
IBe sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
14) After tightening axle nut, lock it securely.
35
[W3E2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

4. Replacement of Front SFJ,
DOJ and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
5) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
6) Remove SFJ, DOJ and BJ boots from drive
shaft. or [W3B2].>
B: INSTALLATION
1) Install SFJ, DOJ and BJ boots to drive shaft.
or
2) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
3) Connect transverse link to housing.
4) Install stabilizer link.
5. Replacement of Rear DOJ
and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
3) Remove ABS sensor clamps and parking brake
cable bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove bolts which secure trailing link assem-
bly to rear housing.
7) Remove crossmember reinforcement lower
from crossmember (4 door model only).
8) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
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
36
4-2[W4A0]SERVICE PROCEDURE
4. Replacement of Front SFJ, DOJ and BJ Boots

4. Replacement of Front SFJ,
DOJ and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
5) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
6) Remove SFJ, DOJ and BJ boots from drive
shaft. or [W3B2].>
B: INSTALLATION
1) Install SFJ, DOJ and BJ boots to drive shaft.
or
2) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
3) Connect transverse link to housing.
4) Install stabilizer link.
5. Replacement of Rear DOJ
and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
3) Remove ABS sensor clamps and parking brake
cable bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove bolts which secure trailing link assem-
bly to rear housing.
7) Remove crossmember reinforcement lower
from crossmember (4 door model only).
8) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
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
36
4-2[W4A0]SERVICE PROCEDURE
4. Replacement of Front SFJ, DOJ and BJ Boots

9) 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
10) Remove DOJ and BJ boots from drive shaft.

B: INSTALLATION
1) Install DOJ and BJ boots to drive shaft.

2) Replace circlips from DOJ spline with new one.
(2200 cc AT vehicles only)3) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0549A
4) Insert DOJ spline end into bore of side oil seal,
and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0550A
5) Align DOJ and differential splines.
6) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
CAUTION:
Discard old self-locking nut. Replace with a
new one.
7) Connect rear housing assembly to trailing link
assembly, and tighten self-locking nut.
8) Connect rear housing assembly to lateral link
37
[W5B0]4-2SERVICE PROCEDURE
5. Replacement of Rear DOJ and BJ Boots