Front Drive Shaft: Assembly

PTJ side: 

NKG302 

1. Place the PTJ boot at the center of shaft.
2. Align alignment marks and install the trunnion on the shaft.
   Fig 1: Identifying Alignment Marks On Trunnion And Shaft

   Courtesy of SUBARU OF AMERICA, INC.
3. Install the snap ring to shaft.
   CAUTION: Confirm that the snap ring is completely fitted in shaft groove.
4. Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of PTJ outer race.
5. Apply a thin coat of specified grease to the roller kit and trunnion.
6. Align alignment marks on roller kit and trunnion and install the roller kit.
   CAUTION: Be careful with the roller kit position.
   Fig 2: Identifying Alignment Marks On Roller Kit And Trunnion

   Courtesy of SUBARU OF AMERICA, INC.
7. Align the alignment marks of the shaft and outer race, and install the outer race.
   Fig 3: Identifying Alignment Marks On Shaft And Outer Race

   Courtesy of SUBARU OF AMERICA, INC.
8. Install the snap ring in the groove on PTJ outer race.
   CAUTION: Pull the shaft lightly and assure that the snap ring is completely fitted in the groove.
9. 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.
10. Install the PTJ boot taking care not to twist it.
    CAUTION:

    • The large end of PTJ boot and the boot groove shall be cleaned completely so as to be free from grease and other substances.
    • When installing PTJ boot, position outer race of PTJ at center of its travel.
11. Put a new band through the clip and wind twice in the band groove of the boot.
12. 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.
13. Tighten the band using the ST.

    ST 925091000 BAND TIGHTENING TOOL

    NOTE: Tighten the band until it cannot be moved by hand.
    Fig 4: Locating Band And ST 925091000 Band Tool

    Courtesy of SUBARU OF AMERICA, INC.
14. Tap the clip with the punch provided at the end of the ST.

    ST 925091000 BAND TIGHTENING TOOL

    CAUTION: Tap to an extent that the boot underneath is not damaged.
    Fig 5: Tapping Clip Using ST 925091000 Band Tool

    Courtesy of SUBARU OF AMERICA, INC.
15. 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.
    CAUTION: Make sure that the end of the band is in close contact with clip.
16. Extend and retract the PTJ to provide equal grease coating.