Drivetrain System: Overhaul Subaru Outback BR

FRONT DRIVE SHAFT ASSEMBLY

FRONT DRIVE SHAFT ASSEMBLY SPECIFICATION

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REAR DRIVE SHAFT ASSEMBLY

REAR DRIVE SHAFT ASSEMBLY SPECIFICATION

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DISASSEMBLY

Using the ST and a hydraulic press, push out the hub bolts.

ST 28399AG000 HUB STAND

Note. Since the hub unit bearing can not be disassembled, only hub bolts can be removed.

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1. Attach the hub to the ST securely. ST 927080000 HUB STAND
2. Using a press, press the new hub bolts until their seating surfaces contact the hub. NOTE: Use the 12 mm (0.47 in) dia. holes in the HUB STAND to prevent bolts from tilting.

Refer to "Rear Trailing Link" of "REAR SUSPENSION" for removal procedures of bushing. Ref. to REAR HOUSING BUSHING , DISASSEMBLY, Rear Trailing Link.

ASSEMBLY

Refer to "Rear Trailing Link" of "REAR SUSPENSION" for installation procedures of bushing. Ref. to REAR HOUSING BUSHING , ASSEMBLY, Rear Trailing Link.

Using the ST and a hydraulic press, push out the hub bolts.

ST 28399AG000 HUB STAND

Note. Since the hub unit bearing can not be disassembled, only hub bolts can be removed.

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1. Attach the hub to the ST securely. ST 927080000 HUB STAND
2. Using a press, press the new hub bolts until their seating surfaces contact the hub. NOTE: Use the 12 mm (0.47 in) dia. holes in the HUB STAND to prevent bolts from tilting.

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1. While moving the rear tire up and down by hand, check if there is no free play in the bearing, and make sure the wheel rotates smoothly.
2. Inspect the play in axial direction using a dial gauge. Replace the hub bearing if the play exceeds the limit. Service limit: Maximum: 0.05 mm (0.0020 in)

Note. Use specified grease.

AAR side: ONE LUBER (C)

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1. Pass the AAR boot through the shaft.
2. Match alignment marks and install the trunnion onto the shaft, and securely install the snap ring to the shaft groove.
3. Fill 50 to 60 g (1.76 to 2.12 oz) of specified grease into the inner side of the AAR outer race.
4. Apply a thin coat of specified grease to the roller and trunnion.
5. Place the drive shaft between wooden blocks etc, and secure it with a vise. CAUTION: Do not clamp the drive shaft directly with vise.
6. Match alignment marks of the shaft and outer race.
7. Tap the upper part of roller insertion on the outer race one after the other, using the plastic or wooden bar, to insert the roller one by one. CAUTION: Do not use the metal rod because it may deform the outer race. Do not tap the outer race tip (shaft part). Be careful not to deform the baffle plate.
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 and grommet taking care not to twist them. CAUTION: Replace the boot and grommet as a set. Make sure the groove on the outer race side is free from grease.
10. Insert a flat tip screwdriver between the outer race and grommet so that the air pressure inside the boot is equal to the atmospheric pressure.
11. Install new large boot band and small boot band to the specified locations.
12. Tighten the boot band using ST, torque wrench and socket flex handle. ST 28099AC000 BOOT BAND PLIER Clearance on the crimped section of boot band: Large boot band 1 mm (0.04 in) or less Small boot band 1 mm (0.04 in) or less
13. Extend and retract the AAR repeatedly to provide an equal coating of grease.

Note. Use specified grease.

BJ, EBJ side: NKG106

DOJ side: NKG205

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1. Install the BJ or EBJ boot in specified position, and fill it with 50 to 60 g (1.76 to 2.12 oz.) of specified grease.
2. Place the DOJ boot at the center of shaft.
3. Insert the DOJ cage onto shaft. NOTE: Insert the cage with the cutout portion facing the shaft end, since the cage has an orientation.
4. Install the DOJ inner race on shaft and fix the snap ring in place with pliers. NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
5. Install the cage to inner race fixed upon shaft. NOTE: Fit the cage with the protruding section aligned with the track on the inner race, and turn by a half pitch.
6. Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the inner side of the DOJ outer race.
7. Apply a thin coat of specified grease to the cage pocket and balls.
8. Insert balls into the cage pocket.
9. Align the outer race track and ball positions, and place the shaft, inner race, cage and ball bearings in the original positions, and then fix outer race in place.
10. Install the snap ring in the groove on the DOJ outer race. NOTE: Assure that the balls, cage and inner race are completely fitted in the outer race of DOJ. Use care not to place the matched position of snap ring in the ball groove of outer race. Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
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 the shaft.
12. Install the DOJ boot taking care not to twist it. NOTE: The inside of the large end of DOJ boot and the boot groove shall be cleaned so as to be free from grease and other substances. When installing the DOJ boot, position the outer race of DOJ at center of the stroke.
13. Put a new band through the clip and wind twice in the band groove of the boot.
14. Pinch the end of band with pliers. Hold the clip and tighten securely. NOTE: When tightening boot, use care so that the air within the boot is appropriate.
15. Tighten the band using the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten the band until it cannot be moved by hand.
16. Tap the clip with the punch provided at the end of the ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tap to an extent that the boot underneath is not damaged.
17. Cut off the band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip. NOTE: Be careful so that the end of the band is in close contact with clip.
18. Install the BJ boot or EBJ boot in the same procedure as a DO J boot.
19. Extend and retract the DOJ repeatedly to provide an equal coating of grease.