Front Drive Shaft: Assembly

AAR side: 

ONE LUBER C 

1. Pass the AAR boot through the shaft.
2. Install the trunnion to the shaft.
   1. Match the alignment marks, and attach the trunnion onto the shaft.
   2. Attach the snap ring to the shaft.
   CAUTION: Confirm that the snap ring is completely fitted in the shaft groove.
   Fig 1: Attaching Snap Ring To Shaft

   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. Install the trunnion to the roller kit.
   1. Apply a thin coat of specified grease to the roller kit and trunnion.
   2. Place the drive shaft between wooden blocks and fix it on a vise.
      CAUTION: Do not set the only drive shaft on a vise.
   3. Align the alignment marks on the shaft and outer race.
   4. Tap the insertion upper part of the outer race alternately using a plastic or wood bar shown in the figure, and then insert the roller one by one.
      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 Insertion Upper Part Of Outer Race Alternately Using Plastic And Wood Bar

      Courtesy of SUBARU OF AMERICA, INC.
   5. 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.
   6. Install the AAR boot and grommet taking care not to twist it.
      CAUTION:

      • Replace the boot and grommet as a set.
      • Do not let grease get on groove of the outer race side.
      Fig 3: Identifying Outer Race, Grommet And Boot

      Courtesy of SUBARU OF AMERICA, INC.
   7. Insert a flat tip screwdriver, etc. between outer race and grommet to make pressure inside of boot as high as barometric pressure.
   8. Tighten the boot band.
      1. Install the new large boot band and small boot band at the required positions.
      2. Connect the torque wrench and socket flex handle to the ST.

      PREPARATION TOOL: 

      ST: BOOT BAND PLIER (28099AC000) 

      Torque wrench 

      Socket flex handle 

   9. Use a prepared tool, tighten the boot band.
   Fig 4: Locating Boot Band And Special Tool

   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 

   Tightening torque: 

   Large boot band: 178 N.m (18.15 kgf-m, 131.3 ft-lb) 

   Small boot band: 145 N.m (14.79 kgf-m, 106.9 ft-lb) 

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