Diesel Data: Automotive Repair
Home >> Subaru >> 1996 >> SVX AWD L6-3.3L DOHC >> Repair and Diagnosis >> Transmission and Drivetrain >> Drive Axles, Bearings and Joints >> Axle Shaft Assembly >> Constant Velocity Joint Boot >> Service and Repair >> Rear

Rear

TOOL REQUIRED
^ 925091000 Band Tightening Tool
^ 925090000 Band Tightening Tool
^ 28099PA090 Side Oil Seal Protector
^ 28099PA100 Drive Shaft Remover

REMOVAL
1. Move select lever to Neutral.
2. Move parking brake lever forward.
3. Lift up vehicle and remove rear wheels.
4. Disconnect rear exhaust pipe.
5. Remove stabilizer link.
6. Remove ABS sensor clamp and parking brake cable bracket.
7. Disconnect parking brake cable clamp.
8. Disconnect brake hose from strut.
9. Disconnect trailing link from housing.
10. Disconnect lateral link from housing.








11. Remove DOJ from rear differential using drive shaft remover. Be careful not to damage side bearing retainer. Always use bolt as supporting point for remover during removal. Left spline end of DOJ is removed together with circlip. Do not remove right circlip attached to inside of differential.





12. Remove DOJ boot band. Be careful not to damage boot.
13. Remove boot from DOJ.





14. Remove circlip from DOJ outer race using screwdriver.
15. Take out DOJ outer race from shaft assy. Do not allow DOJ splines to damage side oil seal.





16. Remove snap ring.





17. Remove DOJ inner race assembly from shaft. Be sure to wrap shaft splices with vinyl tape to prevent boot from scratches.
18. Remove DOJ boot.





19. Remove BJ boot band protector.





20. Remove BJ boot band.
21. Remove BJ boot.

INSPECTION
1. Check the removed parts for damage, wear, corrosion, etc. If faulty, repair or replace.
2. Double Offset Joint (DOJ) and Bell Joint (BJ): Check seizure, corrosion, play.
3. Shaft: Check excessive bending, twisting, damage and wear.
4. Boot: Check for wear, warping, breakage or scratches.
5. Grease: Check for discoloration or fluidity, damage, wear and excessive

INSTALLATION

NOTE: Use specified grease. BJ and DOJ: Molylex No.2 (P/N 723223010) or Sunlight TB2-A. Be sure to wrap shaft splices with vinyl tape to prevent boot from scratches.

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 boot band protector and DOJ boot at the center of shaft.





3. Insert DOJ cage onto shaft. Insert the cage with the cut-out side facing the shaft end, since the cane has an orientation





4. Install DOJ inner race on shaft and fit snap ring with special pliers. Confirm that the snap ring is completely fitted in the shaft groove.





5. Install cage, which was previously fitted, to inner race fixed upon shaft. Fit the cage with the protruded part aligned with the track on the inner race and then turn by a half Ditch.
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.





10. Install circlip in the groove on DOJ outer race.
a. Assure that the balls, cage and inner race are completely fitted in the outer race of DOJ.
b. Exercise care not to place the matched position of circlip in the ball groove of outer race.
c. 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 shaft.
12. Install DOJ boot taking care not to twist it.
a. The 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.
b. When 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. Use a new band.
14. Pinch the end of band with pliers. Hold the clip and tighten securely. When tightening boot, exercise care so that the air within the boot is appropriate.





15. Tighten band by using band tightening tool.
a. Tighten band until it cannot be moved by hand.
b. Former band tightening tool is interchangeable with this 925091000.
16. Tap on the clip with the punch provided at the end of band tightening tool. Tap to an extent that the boot underneath is not damaged.





17. Cut off band with an allowance of about 10 mm (0.39 inch) left from the clip and bend this allowance over the clip. 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.
19. Place protector onto BJ boot band. Extend and retract DOJ to provide equal grease coating. Discard circlip on left DOJ splice, and install new one.





20. Using side oil seal protector, install DOJ into differential





21. Insert DOJ splined end into bore of oil side seal, and remove side oil seal protector. Do not allow DOJ splices to damage side oil seal.
22. Mesh DOJ with differential splines.





23. Push housing to insert DOJ into differential. Check to make sure DOJ is inserted properly.
24. Install remaining parts in reverse order of removal procedures.
25. For installation and tightening torque of suspension parts, refer to specification. For installation and tightening torque of brake parts, refer to Brakes and Traction Control. Use a new self-lock nut.

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