2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. RH LH A B K JLL C D AS f i jre 8 ili L1 K E Ap i Y UN mj too c3 d li L1 di ik K F G D y azdi lil Haiii Eo o EH G H D J M fa Y ml Dpto Too m e gt K DS 00201 DS 4 General Description DRIVE SHAFT SYSTEM A EBJ82 DOJ82 sedan RH E BJ794DOJ79 sedan R152R L I BJ79 DOJ79 wagon R160RH B EBJ82 DOJ82 sedan LH F BJ79 DOJ79 wagon R152R L J BJ79 DOJ79 wagon R160LH C BJ79 DOJ79 sedan R160RH G EBJ82 DOJ82 wagon RH K Identification protrusion D BJ79 DOJ79 sedan R160LH H EBJ824DOJ82 wagon LH L BJ87 DOJ87 R180 RH LH B COMPONENT 1 PROPELLER SHAFT DS 00221 1 Propeller shaft DOJ type 4 Rear differential T type Tightening torque N m kgf m ft Ib 2 Propeller shaft 3UJ type T1 31 3 2 22 9 3 Rear differential VA type T2 52 5 3 38 3 DS 5 General Description DRIVE SHAFT SYSTEM 2 FRONT AXLE EBJ PTJ type T DS 00274 1 Circlip 9 Boot PTJ 17 Housing 2 Baffle plate PTJ 10 Boot EBJ 18 Oil seal OUT 3 Outer race PTJ 11 EBJASSY 19 Hub bolt 4 Snap ring 12 Tone wheel with ABS 20 Hub b Trunnion 13 Baffle plate 21 Axle nut 6 Free ri2. US 1 CO b DS 00069 1 ABS wheel speed sensor 8 Using the ST1 and ST2 pull the rear drive shaft into place ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER DS 00123 9 Tighten a new axle nut to the specified torque with parking brake applied Tightening torque 186 N m 19 kgf m 137 ft lb 10 Lock the axle nut DS 00048 11 Install the wheel Tightening torque 90 N m 9 2 kgf m 66 ft lb 12 Make the tires contact the ground fully CAUTION Make the tires contact the ground fully and the vehicle be in curb weight whenever carrying out the tightening of bush portions 13 Tighten the installation bolt of rear housing as sembly and lateral link assembly Tightening torque 137 N m 14 kgf m 101 ft lb 14 Tighten the installation bolt of rear housing as sembly and trailing link assembly Tightening torque 90 N m 9 2 kgf m 66 ft Ib C DISASSEMBLY 1 Straighten the bent claw of larger end of DOJ boot 2 Loosen the band by means of screwdriver or pli ers with care of not damaging boot DS 00124 3 Remove the boot band on the small end of DOJ boot in the same manner 4 Remove the larger end of DOJ boot from DOJ outer race 5 Pry and remove the round circlip located at neck of DOJ outer race with a screwdriver DS 00125 6 Take out the DOJ outer race from shaft assem bly 7 Wipe off the grea
3. DS 00016 8 Make matching marks on affected parts before removal DS 00028 A Matching mark 9 Remove the three bolts which hold the propeller shaft to rear differential 10 Remove the remaining bolt 11 Remove the two bolts which hold the center bearing to vehicle body DS 00029 12 Remove the propeller shaft from transmission CAUTION Be careful not to damage the oil seals and frictional surface of sleeve yoke Cover the center exhaust pipe with a cloth to keep off any ATF or oil spilled from transmis sion when removing the propeller shaft DS 00030 DS 16 Propeller Shaft 13 Install the extension cap to transmission NOTE If the extension cap is not available place a vinyl bag over opening and fasten it with string to pre vent gear oil or ATF from leaking A Extension cap B INSTALLATION 1 Insert the sleeve yoke into transmission and then attach the center bearing to body Tightening torque 52 N m 5 3 kgf m 38 3 ft Ib DS 00029 2 Align the matching marks and then connect the flange yoke and rear differential Tightening torque 31 N m 3 2 kgf m 22 9 ft Ib DS 00028 A Matching mark 3 Using new bolts install the differential mount front cover DRIVE SHAFT SYSTEM 1 Temporarily tighten the bolt A while push ing cover forward 2 Tighten the bolt B to specifie
4. 101 ft Ib 17 Tighten the installation bolt of rear housing as sembly and trailing link assembly Tightening torque 90 N m 9 2 kgf m 66 ft Ib 2 DRUM BRAKE 1 Temporarily tighten the rear axle to strut 2 Insert the rear drive shaft to rear axle NOTE Be careful not to damage the inner oil seal lip 3 Temporarily tighten the axle nut 4 Using a new self locking nut temporarily tighten the rear housing assembly and lateral link assem bly DS 00067 DRIVE SHAFT SYSTEM 5 Using a new self locking nut temporarily tighten the rear housing assembly and trailing link assem bly DS 00066 6 Tighten the rear housing assembly and strut as sembly using a new self locking nut Tightening torque 196 N m 20 kgf m 145 ft lb 7 Using a new self locking nut install the rear sta bilizer and rear lateral link Tightening torque 44 N m 4 5 kgf m 32 5 ft lb 8 Connect the parking brake cable to parking brake 9 Clean the brake pipe connection Using a flare nut wrench connect the brake pipe to wheel cylin der 10 Connect the parking brake cable to lever 11 Install the brake drum on rear housing assem bly 12 Bleed the air from brake system lt Ref to BR 60 REPLACEMENT Brake Fluid gt 13 Adjust the parking brake lever stroke by turning the adjuster 14 Move the brake lever back to apply brakes While depressing the brake pedal tighten the axle nut using a so
5. 3 3 kgf m 23 9 ft Ib 15 Install the wheel and tighten the wheel nuts to specified torque Tightening torque 90 N m 9 2 kgf m 66 ft Ib DRIVE SHAFT SYSTEM C DISASSEMBLY 1 Using the ST1 support the housing and hub se curely 2 Attach the ST2 to housing and drive the hub out ST1 927060000 HUB REMOVER ST2 927080000 HUB STAND DS 00049 If the inner bearing race remains in hub remove it with a suitable tool commercially available NOTE Be careful not to scratch the polished area of hub DS 00050 CAUTION Do not reuse the bearing if the hub was re moved DS 21 Front Axle DRIVE SHAFT SYSTEM 3 Remove the disc cover from housing DS 00051 4 Using a standard screwdriver remove the outer and inner oil seals 5 Using a flat tip screwdriver remove the snap ring NOTE Be careful not to damage the housing at removal DS 00052 6 Using the ST1 support the housing securely 7 Using the ST2 hold the inner race to drive out the outer race of bearing ST1 927400000 HOUSING STAND ST2 3927100000 BEARING PULLER DS 00053 8 Using the ST and a hydraulic press drive the hub bolts out ST 927080000 HUB STAND J U DS 00054 D ASSEMBLV NOTE When the hub is to be removed from housing re place the bearing set
6. Used with BEARING PULLER 927100000 ILLUSTRATION General Description TOOL NUMBER DESCRIPTION DRIVE SHAFT SYSTEM REMARKS ST 927410000 927410000 OIL SEAL INSTALLER Used for installing oil seal into front housing Used with HOUSING STAND 927400000 2 ST 927430000 927430000 HOUSING STAND Used for disassembling and assembling rear housing bearing Used with BEARING PULLER 927440000 M ST 927120000 927120000 HUB INSTALLER Used for installing hub Q ST 927440000 927440000 BEARING REMOVER DS 13 Used for disassembling and assembling rear wheel bearing Used with HOUSING STAND 927430000 DRIVE SHAFT SYSTEM ILLUSTRATION General Description TOOL NUMBER DESCRIPTION REMARKS cy ST 927460000 927460000 OIL SEAL INSTALLER Used for installing outer oil seal Used with HOUSING STAND 927430000 SCH ST 927450000 927450000 HUB INSTALLER Used for pressing hub bearing into hub Used with HUB STAND 927080000 A ST28099PA090 28099PA090 OIL SEAL PROTEC TOR Used for installing rear drive shaft into rear dif ferential e For protecting oil seal A ST28399SA010 28399SA010 OIL SEAL PROTEC TOR DS 14 e Used for installing front drive shaft to transmis sion e For protecting oil seal General Description ILLUSTRATION TOOL NUMBER DESCR
7. 10 338 8 13 34 Turbo MT STi BJ92 DOJ87 297 6 11 72 Non turbo Turbo AT EBJ87 PTJ82 26 1 02 329 6 12 98 Turbo MT EBJ87 PTJ82 28 1 10 329 6 12 98 D EI b A C Un REY li Lig SEL ES Pei H NL La D gt B C Y Co FSZ sp i SE ES ESL l La MAAN bil DS 00286 A EBJ87 SFJ82 C Axle diameter D Axle length B BJ924DOJ87 DS 3 DRIVE SHAFT SYSTEM General Description 3 REAR DRIVE SHAFT ASSEMBLY Size Model No of identification L1 mm in protrusion on shaft b D mm in EBJ824DOJ82 363 14 29 24 0 94 EBJ824DOJ82 Sedan turbo except for STi 353 13 90 24 0 94 BJ794DOJ79 Sedan 2 0 L Non turbo MT aca Mat BJ794DOJ79 358 14 09 23 0 91 BJ794DOJ79 Sedan 1 6 L 2 0 L Non turbo AT 363 14 29 24 0 94 BJ794DOJ79 Wagon 1 6 L 2 0 L Non turbo AT 355 13 98 EBJ824DOJ82 353 13 90 24 0 94 EBJ82 DOJ82 Wagon turb SS 343 18 50 BJ794DOJ79 358 14 09 23 0 91 BJ794DOJ79 Wagon 2 0 L Non turbo MT 348 13 70 23 0 91 miel TITIO Tn m ool w gt BJ87 DOJ87 295 2 11 62
8. Fix up the boot on BJ in the same manner 19 Extend and retract the DOJ to provide equal grease coating DS 42 Front Drive Shaft DRIVE SHAFT SYSTEM E INSPECTION Check the removed parts for damage wear corro sion etc If faulty repair or replace 1 DOJ Double Offset Joint Check seizure corrosion damage wear and ex cessive play 2 PTJ Pillow tripod Joint Check seizure corrosion damage and excessive play 3 Shaft Check excessive bending twisting damage and wear 4 EBJ High efficiency compact ball fixed joint Check seizure corrosion damage and excessive play 5 Boot Check for wear warping breakage or scratches 6 Grease Check for discoloration or fluidity DS 43 Rear Drive Shaft DRIVE SHAFT SYSTEM 7 Rear Drive Shaft A REMOVAL 1 Disconnect the ground cable from battery 2 Lift up the vehicle and remove the rear wheel 3 Unlock the axle nut NO 4 Remove the axle nut using a socket wrench with parking brake applied CAUTION Remove the axle nut with vehicle weight not ap plied on axle DS 00038 5 Disconnect the stabilizer link RS 00010 6 Remove the bolt which secures the trailing link to housing DS 00066 7 Remove the bolts which secure the front lateral link and rear lateral link to housing DS 00067 8 Remove the rear ABS wheel speed sensor from back plate N EL E
9. INSPEC TION Front Strut Rear strut Check the rear strut Ref to RS 16 INSPEC TION Rear Strut Front drive shaft Check the front drive shaft Ref to DS 43 INSPECTION Front Drive Shaft Rear drive shaft Check the rear drive shaft Ref to DS 49 INSPECTION Rear Drive Shaft Front axle Check the front axle Ref to DS 23 INSPEC TION Front Axle Rear axle Check the rear axle Ref to DS 32 INSPEC TION Rear Axle AWD Model gt Ref to DS 34 INSPECTION Rear Axle FWD Modell Noise from the underbody Wheel is out of balance Check the wheel balance Ref to WT 7 INSPECTION Wheel Balancing Front wheel alignment Check the front wheel alignment Ref to FS 6 INSPECTION INSPECTION Wheel Align ment Rear wheel alignment Check the rear wheel alignment Ref to RS 10 INSPECTION Wheel Alignment Front strut Check the front strut Ref to FS 21 INSPEC TION Front Strut Rear strut DS 50 Check the rear strut Ref to RS 16 INSPEC TION Rear Strut
10. exhaust pipe and muffler 3 Remove the heat shield cover 4 Set the dial gauge with its indicator stem at cen ter of propeller shaft tube 5 Turn the propeller shaft slowly by hands to check for runout of propeller shaft Runout Limit 0 6 mm 0 024 in DS 00036 A Propeller shaft B Dial gauge 4 CENTER BEARING FREE PLAY 1 Remove the front and center exhaust pipes 2 Remove the rear exhaust pipe and muffler 3 Remove the heat shield cover 4 Move the propeller shaft near center bearing up and down and left and right with your hand to check for any abnormal bearing free play DS 00037 DS 18 Front Axle 3 Front Axle A REMOVAL 1 Lift up the vehicle and remove the front wheels 2 Unlock the axle nut SCH 3 Remove the axle nut using a socket wrench while depressing the brake pedal CAUTION Remove the axle nut with vehicle weight not ap plied on axle Failure to follow this rule may damage the wheel bearings 4 Remove the stabilizer link SEDAN DS 00038 FS 00048 FS 00070 5 Remove the disc brake caliper from housing and suspend it from strut using a wire DRIVE SHAFT SYSTEM 6 Remove the disc rotor from hub NOTE If the disc rotor seizes up within hub drive disc rotor out by installing an 8 mm bolt in screw hole on ro tor K DS 00041 7 Rem
11. larger end of DOJ boot and 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 its travel DS 00125 14 Put a new band through the clip and wind twice in alignment with band groove of boot NOTE When tightening the boot exercise care so that air within 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 DS 00284 16 Tap on the clip with the punch provided at the end of ST ST 925091000 NOTE Tap to an extent that the boot underneath is not damaged BAND TIGHTENING TOOL FR DS 00285 17 Cut off the band with an allowance of about 10 mm 0 39 in left from clip and bend this allowance over the clip NOTE Be careful so that the end of band is in close con tact with clip 18 Fix up the boot on BJ in the same manner 19 Extend and retract the DOJ to provide equal grease coating DS 48 Rear Drive Shaft DRIVE SHAFT SYSTEM E INSPECTION Check the removed parts for damage wear corro sion etc If faulty repair or replace 1 DOJ Double Offset Joint Check seizure corrosion damage wear and ex cessive play 2 Shaft Check excessive bending twisting damage and wear 3 BJ Bell Joint Check seizure corrosion damage and excessive play 4 EBJ H
12. there is no backlash in bearing and check the wheel rotates smoothly DS 00061 2 Inspect the lean of axis direction using a dial gauge Replace the hub bearing if the load range exceeds the limitation Limit Maximum 0 05mm 0 0020 in DS 00062 DS 32 Rear Axle FWD Model 5 Rear Axle FWD Model A REMOVAL CAUTION Remove the axle nut with vehicle weight not ap plied on axle Failure to follow this rule may damage the wheel bearings 1 Apply the parking brake 2 Lift up the vehicle and remove the rear wheel CAUTION In case of model with aluminum wheels be care not to damage them 3 Release the caulking of axle nut 4 Remove the axle nut by socket wrench of 32 mm CAUTION Remove the axle nut with wheel removed DS 00276 5 Release the parking brake loosen the adjuster 6 Remove the drum brake from hub lt Ref to BR 49 REMOVAL Rear Drum Brake Drum gt 7 Using a flare nut wrench disconnect the brake pipe from wheel cylinder CAUTION Cover the brake pipe connection to protect it from dust 8 Separate the rear spindle from lateral link as sembly CAUTION Do not reuse the self locking nut 9 Separate the rear spindle from trailing link as sembly DRIVE SHAFT SYSTEM CAUTION Do not reuse the self locking nut DS 00277 A Trailing link B Lateral link 10 Remove the bolt which combines the rear spin dle and
13. to be free from grease and other sub stances 5 Install the boot projecting portion to EBJ groove V DS 00114 A EBJ B Large boot band C Boot 6 Set the large boot band in place 7 Install the boot projecting portion to shaft groove B by L DS 00115 gt Boot B Small boot band C Shaft 8 Tighten the boot bands using the ST torque wrench and socket flex handle DS 39 Front Drive Shaft DRIVE SHAFT SYSTEM ST 28099AC000 BOOT BAND PLIER ST DS 00116 A Large boot band B Boot C Torque wrench D Socket flex handle E EBJ nasan Tightening torque Large boot band 157 N m 16 0 kgf m 116 ft lb or more Small boot band 133 N m 13 6 kgf m 98 ft Ib or more 9 Place the PTJ boot at the center of shaft 10 Align the alignment marks and then install the trunnion on shaft DS 00110 11 Install the snap ring to shaft CAUTION Confirm that the snap ring is completely fitted in shaft groove 12 Fill 100 to 110 g 3 53 to 3 88 oz of specified grease into the interior of PTJ outer race 13 Apply a coat of specified grease to free ring and trunnion 14 Align the alignment marks on free ring and trun nion and then install the free ring CAUTION Be careful with the free ring position DS 00208 15 Align the alignment mark
14. 065 1 Cable end DRIVE SHAFT SYSTEM 11 Disconnect the rear stabilizer from rear lateral link Remove the bolts which secure the trailing link assembly to rear housing DS 00066 12 Remove the bolts which secure the lateral link assembly to rear housing DS 00067 13 Remove the rear ABS wheel speed sensor from back plate YO 1 DS 00069 1 ABS wheel speed sensor 14 Disengage the BJ from housing splines and re move the rear drive shaft assembiv If itis hard to remove use the STs ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION Becareful not to damage the oil seal lip when removing the rear drive shaft DS 27 Rear Axle AWD Model DRIVE SHAFT SYSTEM When the rear drive shaft is to be replaced also replace the inner oil seal with a new one DS 00068 15 Remove the bolts which secure the rear hous ing to strut and separate the two DS 00070 B INSTALLATION 1 DISC BRAKE 1 Temporarily tighten the rear axle to strut 2 Insert the rear drive shaft into rear axle NOTE Be careful not to damage the inner oil seal lip 3 Temporarily tighten the axle nut 4 Using a new self locking nut temporarily tighten the rear housing assembly and lateral link assem bly DS 00067 5 Using a new self locking nut temporarily tighten the rea
15. 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION RS WHEEL AND TIRE SYSTEM WT DIFFERENTIALS DI This service manual has been prepared to provide SUBARU service personnel with the necessarv information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of ABS ABS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition BRAKE BR When replacement of parts during repair work is needed be sure to use SUBARU genuine parts PARKING BRAKE PB TRANSFER CASE TC DRIVE SHAFT SYSTEM DS ABS DIAGNOSTICS ApBSidtag POWER ASSISTED SYSTEM POWER STEERING All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G1870GE5 A DRIVE SHAFT SYSTEM 09 O T En Page General Description deeg e e aa a idu 2 Propeller Shaft a er ttn reru ete b e Cep ede a ne RE red 16 Ereegnes e ee e deeg eege 19 Rear Axle AWD Modell 25 Rear Axle FWD Modell 33 Front Drive EE 36 PELINI eRe GE 44 General Diagnostic Table irure B 50 General De
16. 430000 HOUSING STAND ST2 927440000 BEARING REMOVER DS 00090 6 Remove the tone wheel bolts and then remove the tone wheel from hub Model with ABS 7 Using the ST press the hub bolt out ST 927080000 HUB STAND CAUTION Be careful not to hammer the hub bolts This may deform the hub D DS 00054 DS 30 Rear Axle AWD Model DRIVE SHAFT SYSTEM D ASSEMBLY NOTE When the hub is to be removed from housing re place the bearing set and oil seal with new ones 1 Using the ST press the new hub bolt into place NOTE Ensure the hub bolt closely contacts the hub Use a 12 mm 0 47 in hole in the ST to prevent the hub bolt from tilting during installation ST 927080000 HUB STAND d se 2 Remove foreign particles dust rust etc from mating surfaces of the hub tone wheel and then in stall the tone wheel to hub Model with ABS NOTE Ensure the tone wheel closely contacts the hub Be careful not to damage the tone wheel teeth DS 00055 DS 00093 1 Tone wheel 3 Clean the housing interior completely Using the ST1 and ST2 press the bearing into housing ST1 927430000 HOUSING STAND ST2 927440000 BEARING REMOVER NOTE Always press the outer race when installing the bearing Be careful not to remove the plastic lock from in ner ra
17. ELL 6459N NOTE f specified grease is not available remove the bearing grease and apply Auto Rex A instead Do not mix different types of grease 10 Install the disc cover to housing with three bolts Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 11 Attach the hub to ST1 securely 12 Clean dust or foreign particles from the pol ished surface of hub 13 Using the ST2 press the bearing into hub by driving the inner race ST1 927080000 HUB STAND ST2 927120000 HUB INSTALLER ST2 o DS 00060 E INSPECTION 1 Moving the front tire up and down by hand check there is no backlash in bearing and check the wheel rotates smoothiv DS 00061 2 Inspect the lean of axis direction using a dial gauge Replace the hub bearing if the load range exceeds the limitation DS 23 Front Axle DRIVE SHAFT SYSTEM Limit Maximum 0 05 mm 0 0020 in DS 00062 DS 24 Rear Axle AWD Model 4 Rear Axle AWD Model A REMOVAL 1 DISC BRAKE 1 Disconnect the ground cable from battery 2 Lift up the vehicle and remove the rear wheel 3 Unlock the axle nut 4 Remove the axle nut using a socket wrench with parking brake applied CAUTION Remove the axle nut with vehicle weight not ap plied on axle Failure to follow this rule may damage the wheel bearings 5 Return the parking brake lever and loosen the adjusting nut 1 Parking brake lever 2 Loc
18. FT INSTALLER ST2 927390000 ADAPTER DS 00104 4 Tighten the axle nut temporarily 5 Using the ST install the front drive shaft to trans mission ST 283998A010 OIL SEAL PROTECTOR ER 6 Connect the transverse link to housing Tightening torque 49 N m 5 0 kgf m 36 ft Ib 7 Install the stabilizer bracket 8 While depressing the brake pedal tighten the axle nut to specified torque DS 36 Front Drive Shaft Tightening torque 220 N m 22 4 kgf m 162 ft Ib CAUTION Always tighten the axle nut before installing wheel on vehicle If the tire is installed and comes in contact with ground when axle nut is loose wheel bearings may be damaged Be sure to tighten the axle nut to specified torque Do not overtighten it as this may dam age the wheel bearing 9 After tightening the axle nut caulk and lock it C DISASSEMBLY 1 EBJ PTJ TYPE 1 Place alignment marks on shaft and outer race DS 00106 2 Remove the PTJ boot band and boot CAUTION Be careful not to damage the boot DS 00107 3 Remove the circlip from PTJ outer race using a screwdriver DS 00108 DRIVE SHAFT SYSTEM 4 Remove the PTJ outer race from shaft assem bly 5 Wipe off the grease CAUTION The grease is a special grease Do not confuse with other greases 6 Place alignment marks on free ring and trunnion DS 00208 7 Remo
19. IPTION DRIVE SHAFT SYSTEM REMARKS 28099PA100 ST28099PA100 DRIVE SHAFT REMOVER Used for removing rear drive shaft from rear dif ferential 28099AC000 ST28099AC000 2 GENERAL PURPOSE TOOLS TOOL NAME BOOT BAND PLI ERS Used for tightening front BU boot band REMARKS Puller Used for removing ball joint from knuckle arm Dial gauge Used for inspecting propeller shaft run out Snap ring pliers Used for installing and removing snap ring Bar DS 15 Used for removing drive shaft Propeller Shaft DRIVE SHAFT SYSTEM 2 Propeller Shaft A REMOVAL NOTE Before removing the propeller shaft wrap the metal parts with a cloth or rubber material n case of DOJ type before removing the propel ler shaft wrap the metal parts installed at the rub ber boot of center DOJ with a cloth or rubber material as shown in the figure Rubber boot may be damaged due to interference with adjacent met al parts while bending the DOJ during removal a pod DS 00026 1 Disconnect the ground cable from battery 2 Move the select lever or gear shift lever to N 3 Release the parking brake 4 Jack up the vehicle and support it with sturdy racks 5 Remove the center exhaust pipes 6 Remove the rear exhaust pipe and muffler 7 Remove the differential mount front cover 6 e
20. L 1 Jack up the vehicle support it with rigid racks and then remove the front wheel cap and wheels 2 Raise the caulking portion of axle nut 3 Depress the brake pedal and remove the axle nut using a socket wrench CAUTION Be sure to loosen the axle nut after removing the wheel from vehicle Failure to follow this rule may damage the wheel bearings 4 Remove the stabilizer link from transverse link 5 Disconnect the transverse link from housing 6 Remove the front drive shaft assembly If it is hard to remove use the ST1 and ST2 ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION Be careful not to damage the oil seal lip and tone wheel when removing the front drive shaft When the front drive shaft is to be replaced also replace the inner oil seal DS 00040 7 Remove the front drive shaft from transmission using bar CAUTION Be careful not to damage the holder portion B INSTALLATION 1 Using the ST replace the differential side retain er oil seal with a new one ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER NOTE After pulling out the drive shaft be sure to replace with a new oil seal MT 00103 2 Insert the EBJ into hub splines CAUTION Be careful not to damage the inner oil seal lip and tone wheel 3 Using the ST1 and ST2 pull the drive shaft into place ST1 922431000 AXLE SHA
21. OJ side NKG205 Part No 28395FE020 1 Install the BJ boot in specified position and fill it with 60 to 70 g 2 12 to 2 47 oz of specified grease 2 Place the DOJ boot at the center of shaft 3 Wrap the shaft splines with vinyl tape DRIVE SHAFT SYSTEM 4 Insert the DOJ cage onto shaft NOTE Insert the cage with cut out portion facing the shaft end since the cage has an orientation DS 00127 A Cage B Cut out portion 5 Install the DOJ inner race on shaft and fit the snap ring with pliers NOTE Confirm the snap ring is completely fitted in shaft groove DS 00128 6 Install the cage which was previously fitted to inner race fixed upon shaft NOTE Fit the cage with protruded part aligned with the track on inner race and then turn by a half pitch DS 00129 A Inner race B Cage DS 41 Front Drive Shaft DRIVE SHAFT SYSTEM 7 Fill 80 to 90 g 2 82 to 3 17 oz of specified grease into the interior of DOJ outer race 8 Apply a coat of specified grease to cage pocket and six balls 9 Insert six balls into cage pocket 10 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 the outer race DS 00126 A Outer race B Grease 11 Install the circlip in the groove on DOJ outer race N
22. OTE Assure the balls cage and inner race are com pletely fitted in the outer race of DOJ Exercise care not to place the matched position of circlip in ball groove of outer race Pull the shaft lightly and assure that the circlip is completely fitted in groove V n IN 12 Applv 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 13 Install the DOJ boot taking care not to twist it NOTE Inside of the larger end of DOJ boot and 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 its travel DS 00125 14 Put a new band through the clip and wind twice in alignment with band groove of boot NOTE When tightening the boot exercise care so that air within 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 DS 00132 16 Tap on the clip with the punch provided at the end of ST ST 925091000 NOTE Tap to an extent that the boot underneath is not damaged BAND TIGHTENING TOOL FR DS 00133 17 Cut off the band with an allowance of about 10 mm 0 39 in left from clip and bend this allowance over the clip NOTE Be careful so that the end of band is in close con tact with clip 18
23. and oil seal with new ones 1 Attach the hub to ST securelv ST 927080000 HUB STAND DS 00055 2 Using a hydraulic press press new hub bolts un til their seating surfaces contact the hub NOTE Use 12 mm 0 47 in dia holes in HUB STAND to prevent bolts from tilting 3 Clean dust or foreign particles from inside of housing 4 Using the ST1 and ST2 press a new bearing into place ST1 927400000 HOUSING STAND ST2 927100000 BEARING PULLER NOTE Always press the outer race when installing the bearing DS 22 Front Axle Be careful not to remove the plastic lock from in ner race when installing the bearing ST2 o H O STI N 5 Using pliers install the snap ring firmly DS 00056 DS 00057 6 Using the ST1 and ST2 press the outer oil seal until it contacts the bottom of housing ST1 927410000 OIL SEAL INSTALLER ST2 927400000 HOUSING STAND ST1 LAT 7 Using the ST1 and ST2 press the inner oil seal until it contacts the circlip ST1 927410000 OIL SEAL INSTALLER ST2 927400000 HOUSING STAND ST2 DS 00058 DS 00059 DRIVE SHAFT SYSTEM 8 Invert the ST and housing ST 927400000 HOUSING STAND 9 Apply sufficient grease to the oil seal lip Specified grease SH
24. ber adjusting bolt head tighten the housing and strut using a new self locking nut Tightening torque 175 N m 17 8 kgf m 129 ft lb 6 Connect the tie rod end ball joint to the knuckle arm with a castle nut Tightening torque 27 0 N m 2 75 kgf m 19 9 ft lb CAUTION When connecting do not hit the cap at bottom of tie rod with hammer 7 Tighten the castle nut to specified torque and tighten further within 60 until the pin hole is aligned with the slot in nut Bend the cotter pin to lock AN i DS 00042 A Cotter pin B Castle nut C Tie rod 8 Install the disc rotor on hub DS 20 Front Axle 9 Install the disc brake caliper on housing Tightening torque 80 N m 8 2 kgf m 59 ft Ib 10 Connect the stabilizer link Tightening torque 45 N m 4 6 kgf m 33 ft Ib CAUTION Use a new self locking nut 11 Using the ST1 and ST2 pull the front drive shaft into place ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER DS 00104 12 While depressing the brake pedal tighten a new axle nut to specified torque and lock it secure ly Tightening torque 220 N m 22 4 kgf m 162 ft Ib CAUTION Be sure to tighten the axle nut to specified torque Do not overtighten it as this may dam age the wheel bearing 13 After tightening the axle nut lock it securely DS 00048 14 Install the ABS wheel speed sensor on hous ing Tightening torque 32 N m
25. ce when installing the bearing DS 00094 4 Using pliers install the snap ring firmly DS 00095 1 Pliers 5 Using the ST1 and ST2 press the outer oil seal until it comes in contact with snap ring ST1 927430000 HOUSING STAND ST2 927460000 OIL SEAL INSTALLER DS 00096 1 Snap ring 6 Invert both ST1 and housing 7 Using the ST2 press the inner oil seal into hous ing until it touches the bottom ST1 927430000 HOUSING STAND DS 31 Rear Axle AWD Model DRIVE SHAFT SYSTEM ST2 927460000 OIL SEAL INSTALLER den DS 00097 8 Using the ST1 and ST2 press the sub seal into place ST1 927430000 HOUSING STAND ST2 927460000 OIL SEAL INSTALLER ST2 DS 00098 9 Apply sufficient grease to oil seal lip Specified grease SHELL 6459N NOTE f specified grease is not available remove the bearing grease and apply Auto Rex A instead Do not mix different types of grease 10 Install the back plate to rear housing Tightening torque 52 N m 5 3 kgf m 38 3 ft Ib 11 Using the ST1 and ST2 press the bearing into hub ST1 927080000 HUB STAND ST2 927450000 HUB INSTALLER ST2 J y i STI DS 00169 1 Back plate E INSPECTION 1 Moving the rear tire up and down by hand check
26. cket wrench Lock the axle nut after tightening Tightening torque 190 N m 19 4 kgf m 140 ft lb CAUTION Do not overtighten it as this may damage the wheel bearing DS 29 Rear Axle AWD Model DRIVE SHAFT SYSTEM 15 Connect the rear ABS wheel speed sensor to back plate N nme RE d DS 00069 1 ABS wheel speed sensor 16 Install the wheel and tighten the wheel nuts to specified torque Tightening torque 90 N m 9 2 kgf m 66 ft Ib 17 Make the tires contact the ground fully CAUTION Make the tires contact the ground fully and the vehicle be in curb weight whenever carrying out the tightening of bush portions 18 Tighten the installation bolt of rear housing as sembly and lateral link assembly Tightening torque 137 N m 14 kgf m 101 ft Ib 19 Tighten the installation bolt of rear housing as sembly and trailing link assembly Tightening torque 90 N m 9 2 kgf m 66 ft Ib C DISASSEMBLY 1 Using the ST1 and ST2 remove the hub from rear housing ST1 927080000 HUB STAND ST2 927420000 HUB REMOVER DS 00088 2 Remove the back plate from rear housing 3 Using a standard screwdriver remove the outer and inner oil seals 4 Using a flat tip screwdriver remove the snap ring NOTE Be careful not to damage the housing at removal DS 00089 5 Using the ST1 and ST2 remove the bearing by pressing the inner race ST1 927
27. d torque 3 Tighten the bolt A to specified torque 4 Tighten the remaining bolts to specified torque Tightening torque 90 N m 9 2 kgf m 66 ft lb DS 00020 4 Install the center exhaust pipes 5 Install the rear exhaust pipe and muffler C INSPECTION NOTE Do not disassemble the propeller shaft Check the following and replace if necessary 1 Tube surfaces for dents or cracks 2 Splines for deformation or abnormal wear 3 Joints for non smooth operation or abnormal noise 4 Center bearing for free play noise or non smooth operation 5 Oil seals for abnormal wear or damage 6 Center bearing for breakage Check the following points with propeller shaft in stalled in vehicle 1 JOINTS AND CONNECTIONS 1 Remove the center exhaust pipes 2 Remove the heat shield cover 3 Check for any looseness of the yoke flange mounting bolts which connect to rear differential and center bearing bracket mounting bolts DS 17 Propeller Shaft DRIVE SHAFT SYSTEM 2 SPLINES AND BEARING LOCATIONS 1 Remove the center exhaust pipes 2 Remove the rear exhaust pipe and muffler 3 Remove the heat shield cover 4 Turn the propeller shaft by hand to see if abnor mal free play exists at splines Also move the yokes to see if abnormal free play exists at spiders and bearings DS 00035 3 RUNOUT OF PROPELLER SHAFT 1 Remove the center exhaust pipes 2 Remove the rear
28. igh efficiency compact ball fixed joint Check seizure corrosion damage and excessive play 5 Boot Check for wear warping breakage or scratches 6 Grease Check for discoloration or fluidity DS 49 DRIVE SHAFT SYSTEM General Diagnostic Table 8 General Diagnostic Table A INSPECTION NOTE Vibration while cruising may be caused by an unbalanced tire improper tire inflation pressure improper wheel alignment etc Symptom Possible cause Corrective action Noise or vibration from propeller shaft Center bearing Check the center bearing Ref to DS 18 CEN TER BEARING FREE PLAY INSPECTION Propeller Shaft Runout of propeller shaft Check the vibration of propeller shaft Ref to DS 18 RUNOUT OF PROPELLER SHAFT INSPECTION Propeller Shaft Loose or free play of connection Check joint and connector Ref to DS 17 JOINTS AND CONNECTIONS INSPECTION Propeller Shaft Check splines and bearing Ref to DS 18 SPLINES AND BEARING LOCATIONS INSPECTION Propeller Shaft Abnormal wheel vibration Wheel is out of balance Check the wheel balance Ref to WT 7 INSPECTION Wheel Balancing Front wheel alignment Check the front wheel alignment Ref to FS 6 INSPECTION Wheel Alignment Rear wheel alignment Check the rear wheel alignment Ref to RS 10 INSPECTION Wheel Alignment Front strut Check the front strut Ref to FS 21
29. k nut 3 Adjusting nut 6 Remove the disc brake caliper from back plate and suspend it from strut using a piece of wire 7 Remove the disc rotor from hub NOTE If the disc rotor seizes up within hub drive it out by installing an 8 mm bolt into bolt hole in disc rotor DRIVE SHAFT SYSTEM 8 Disconnect the parking brake cable end DS 00065 1 Cable end 9 Disconnect the rear stabilizer from rear lateral link 10 Remove the bolts which secure the trailing link assembly to rear housing DS 00066 11 Remove the bolts which secure the lateral as sembly to rear housing DS 00067 DS 25 Rear Axle AWD Model DRIVE SHAFT SYSTEM 12 Remove the rear ABS wheel speed sensor from back plate d Vy 1 cS N DS 00069 1 ABS wheel speed sensor 13 Disengage the BJ from housing splines and then remove the rear drive shaft assembly If itis hard to remove use the STs ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE NOTE Be careful not to damage the oil seal lip when re moving the rear drive shaft When the rear drive shaft is to be replaced also replace the inner oil seal with a new one ST2 DS 00068 14 Remove the bolts which secure the rear hous ing to strut and separate the two DS 00070 2 DRUM BRAKE 1 Disconnec
30. n en d DS 00069 1 ABS wheel speed sensor 9 Remove the rear drive shaft from rear axle If it is hard to remove remove the brake disk rotor using the ST1 and ST2 ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION Do not hammer the drive shaft when remov ing Do not damage the oil seal and tone wheel DS 00122 10 Remove the rear drive shaft from rear differen tial using the ST ST 208099PA100 DRIVE SHAFT REMOVER DS 44 Rear Drive Shaft NOTE Fit the ST to the bolt A as shown in the figure to avoid damage on the side bearing retainer DI 00206 B INSTALLATION 1 Insert the rear drive shaft into rear axle 2 Temporarily tighten the axle nut 3 Install the rear drive shaft to rear differential us ing the ST ST 28099PA090 OIL SEAL PROTECTOR DI 00060 DRIVE SHAFT SYSTEM 4 Temporarily tighten the front lateral link and rear lateral link to housing using a new self locking nuts DS 00067 5 Temporarily tighten the trailing link to housing using a new self locking nut DS 00066 6 Install the stabilizer link Tightening torque 45 N m 4 6 kgf m 33 ft lb RS 00010 7 Install the ABS wheel speed sensor DS 45 Rear Drive Shaft DRIVE SHAFT SYSTEM Tightening torque 32 N m 3 3 kgf m 24 ft Ib
31. ng 14 Oil seal IN 7 Circlip 15 Snap ring Tightening torque N m kgf m ft Ib 8 Boot band 16 Bearing T 220 22 4 162 DS 6 General Description DRIVE SHAFT SYSTEM e BJ DOJ type 1 2 C A 13 21 T DS 00287 1 Circlip 10 Boot EBJ 19 Hub bolt 2 Baffle plate 11 EBJ ASSY 20 Hub 3 Outer race PTJ 12 Tone wheel with ABS 21 Axle nut 4 Snap ring 13 Baffle plate 22 Snap ring 5 Inner race 14 Oil seal IN 6 Ball 15 Snapring Tightening torque N m kgf m ft Ib 7 Cage 16 Bearing T 220 22 4 162 8 Boot band 17 Housing 9 Boot PTJ 18 Oil seal OUT DS 7 General Description DRIVE SHAFT SYSTEM 3 REAR AXLE e AWD model DS 00222 1 Circlip 11 Boot 20 Tone wheel 2 Baffle plate DOJ 12 Non turbo BJ ASSY 21 Hub bolt 3 Outer race DOJ Turbo EBJ ASSY 22 Hub 4 Snap ring 13 Baffle plate 23 Axle nut 5 Inner race 14 Oil seal IN No 2 6 Ball 15 Oil seal IN Tightening torque N m kgf m ft Ib 7 Cage 16 Housing Ti 13 1 3 9 4 8 Circlip 17 Bearing T2 190 19 4 140 9 Boot band 18 Snap ring 10 Boot DOJ 19 Oil seal OUT DS 8 e FWD model General Description DRIVE SHAFT SYSTEM 5 6 e Ki 7 PX 8 PR
32. nstall the DOJ inner race on shaft and fit the snap ring with pliers NOTE Confirm the snap ring is completely fitted in shaft groove DS 00128 6 Install the cage which was previously fitted to inner race fixed upon shaft NOTE Fit the cage with protruded part aligned with the track on inner race and then turn by a half pitch DS 00129 A Inner race B Cage DS 47 Rear Drive Shaft DRIVE SHAFT SYSTEM 7 Fill 80 to 90 g 2 82 to 3 17 oz of specified grease into the interior of DOJ outer race 8 Apply a coat of specified grease to cage pocket and six balls 9 Insert six balls into cage pocket 10 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 the outer race DS 00126 A Outer race B Grease 11 Install the circlip in the groove on DOJ outer race NOTE Assure the balls cage and inner race are com pletely fitted in the outer race of DOJ Exercise care not to place the matched position of circlip in ball groove of outer race Pull the shaft lightly and assure that the circlip is completely fitted in groove V n IN 12 Applv 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 13 Install the DOJ boot taking care not to twist it NOTE Inside of the
33. on T2 DS 00275 1 Rear spindle 5 Washer Tightening torque N m kgf m ft Ib 2 Tone wheel 6 Axle nut T1 6 0 6 4 4 3 Hub bolt 7 O ring T2 190 19 4 140 4 Hub 8 Hubcap DS 9 General Description DRIVE SHAFT SYSTEM C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during operation e Remove contamination including dirt and corro sion before removal installation or disassembly Keep the disassembled parts in order and pro tect them from dust or dirt Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement e Be careful not to burn your hands because each part on the vehicle is hot after running D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION Use SUBARU genuine grease etc or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or rigid racks at the specified points Apply grease onto sliding or revolution surfaces before installation Before installing snap rings apply sufficient amount of grease to avoid damage and deforma tion Before securing a part on a vise place cushion ing material such as wood blocks aluminum plate or shop cl
34. oth between the part and the vise REMARKS ow A c ST 922431000 AXLE SHAFT INSTALLER e Used for installing axle shaft into housing e Used with ADAPTER 927390000 925091000 ST 925091000 TOOL BANDTIGHTENING Used for tightening boot band A Jig for band B Ratchet wrench DS 10 ILLUSTRATION General Description TOOL NUMBER DESCRIPTION DRIVE SHAFT SYSTEM REMARKS 926470000 AXLE SHAFT PULLER Used for removing axle shaft ST 927060000 927060000 HUB REMOVER Used for removing front hub Used with HUB STAND 927080000 ST 927420000 927420000 HUB REMOVER Used for removing rear hub Used with HUB STAND 927080000 ST 927080000 927080000 HUB STAND DS 11 Used for disassembling and assembling hub bolt in hub DRIVE SHAFT SYSTEM ILLUSTRATION General Description TOOL NUMBER DESCRIPTION REMARKS ST 927100000 927100000 BEARING PULLER Used for disassembling and assembling front housing bearing Used with HOUSING STAND 927400000 ST 927140000 927140000 AXLE SHAFT PULLER PLATE Same as plate 2 included in AXLE SHAFT PULLER 926470000 J D ST 927390000 927390000 ADAPTER Used as an adapter for AXLE SHAFT INSTALLER 922431000 ST 927400000 927400000 HOUSING STAND DS 12 Used for disassembling and assembling front housing bearing
35. ove the cotter pin and castle nut which se cure tie rod end to housing knuckle arm f H DS 00042 A Cotter pin B Castle nut C Tie rod 8 Using a puller remove the tie rod ball joint from knuckle arm DS 00043 DS 19 Front Axle DRIVE SHAFT SYSTEM 9 Remove the ABS wheel speed sensor assembly and harness B R 2 5 5 5 DS 00044 10 Remove the transverse link ball joint from housing DS 00045 11 Remove the front drive shaft assembly from hub If it is hard to remove use the STs ST1 926470000 AXLE SHAFT PULLER ST2 927140000 AXLE SHAFT PULLER PLATE CAUTION Be sure to replace the differential side retain er oil seal at transmission side with a new one when removing the front drive shaft Suspend the front drive shaft to vehicle body using a wire DS 00040 12 After scribing an alignment mark on the camber adjusting bolt head remove the bolts which con nect the housing and strut and disconnect the housing from strut DS 00046 B INSTALLATION 1 Temporarily tighten the front axle to front strut 2 Insert the front drive shaft into front axle 3 Temporarily tighten the axle nut 4 Install the transverse link ball joint to housing Tightening torque 50 N m 5 1 kgf m 37 ft lb 5 While aligning the alignment mark on the cam
36. r housing assembly and trailing link assem bly DS 00066 6 Tighten the rear housing assembly and strut as sembly using a new self locking nut Tightening torque 196 N m 20 kgf m 145 ft lb 7 Using a new self locking nut install the rear sta bilizer and rear lateral link Tightening torque 44 N m 4 5 kgf m 32 5 ft Ib 8 Connect the parking brake cable to parking brake 9 Install the disc rotor on rear housing assembly 10 Install the disc brake caliper on back plate Tightening torque 52 N m 5 3 kgf m 38 3 ft Ib DS 00064 11 Adjust the parking brake lever stroke by turning the adjuster 12 While applying the parking brake tighten a new axle nut using a socket wrench Lock the axle nut after tightening Tightening torque 190 N m 19 4 kgf m 140 ft lb CAUTION Do not overtighten it as this may damage the wheel bearing DS 28 Rear Axle AWD Model 13 Install rear ABS wheel speed sensor N ER n 1 ABS wheel speed sensor 14 Install the wheel and tighten the wheel nuts to specified torque Tightening torque 90 N m 9 2 kgf m 66 ft Ib 15 Make the tires contact the ground fully CAUTION Make the tires contact the ground fully and the vehicle be in curb weight whenever carrying out the tightening of bush portions 16 Tighten the installation bolt of rear housing as sembly and lateral link assembly Tightening torque 137 N m 14 kgf m
37. s on shaft and outer race and then install the outer race d l 16 Install the circlip in the groove on PTJ outer race CAUTION Pull the shaft lightly and assure the circlip is completely fitted in 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 the PTJ boot taking care not to twist it CAUTION e PTJ installation surface of PTJ boot shall be cleaned so as to be free from grease and other substances When installing the PTJ boot position the outer race of PTJ at center of its travel 19 Put a new band through the clip and wind twice in alignment with band groove of boot n DS 00106 DS 40 Front Drive Shaft 20 Tighten the band by using the ST ST 925091000 BAND TIGHTENING TOOL NOTE Tighten the band until it cannot be moved by hand DS 00132 21 Tap on the clip with punch provided at the end of ST ST 925091000 CAUTION Tap to an extent that the boot underneath is not damaged BAND TIGHTENING TOOL WAN DS 00133 22 Cut off the band with an allowance of about 10 mm 0 39 in left from clip and bend this allowance over clip CAUTION Be careful so that the end of band is in close contact with clip 23 Extend and retract the SFJ to provide equal grease coating 2 BJ DOJ TYPE NOTE Use specified grease BJ side NTG2218 M Part No 28395FE010 D
38. scription DRIVE SHAFT SYSTEM 1 General Description A SPECIFICATIONS 1 PROPELLER SHAFT 7 Turbo except STi model STi model Mod l Monte for STi without DCCD with DCCD Propeller shaft type UJ DOJ UJ UJ Front propeller shaft Joint to joint length mm in AT 584 22 99 579 22 79 L4 MT 643 25 32 638 25 12 584 22 99 574 22 60 Rear propeller shaft Joint to joint length Lo mm in 708 27 87 713 28 07 708 27 87 706 27 80 Di 63 5 2 500 70 2 756 Outer diameter of tube mm in D2 57 0 2 244 A Di D2 g SCH Ge lis L1 i Lo T P3 B B Di s Y y T ES DS 00001 A UJ type B DOJ type DS 2 General Description DRIVE SHAFT SYSTEM 2 FRONT DRIVE SHAFT ASSEMBLY Model Type of drive shaft nee diameter eB Axle length L mm in mm in Non turbo Turbo AT EBJ87 PTJ82 26 1 02 338 8 13 34 Turbo MT except STi EBJ87 PTJ82 28 1
39. se and then take out the balls NOTE The grease is a special grease grease for con stant velocity joint Do not confuse with other greases DS 46 Rear Drive Shaft DRIVE SHAFT SYSTEM Disassemble with exercising care not to lose balls 6 pcs DS 00126 A Outer race B Grease 8 To remove the cage from inner race turn the cage by a half pitch to the track groove of inner race and shift the cage 9 Remove the snap ring which fixes the inner race to shaft by using pliers 10 Take out the DOJ inner race 11 Take off the DOJ cage from shaft and remove the DOJ boot 12 Wrap the shaft splines with vinyl tape 13 Remove the BJ boot or EBJ boot in the same procedure as DOJ boot NOTE Further disassembly of axle is impossible because the BJ and EBJ cannot be disassembled D ASSEMBLY NOTE Use specified grease EBJ side NTG2218 M Part No 28395AG000 BJ side NTG2218 M Part No 28395FE010 DOJ side NKG205 Part No 28395FE020 1 Install the BJ boot or EBJ boot in specified posi tion and fill it with 60 to 70 g 2 12 to 2 47 oz of specified grease 2 Place the DOJ boot at the center of shaft 3 Wrap the shaft splines with vinyl tape 4 Insert the DOJ cage onto shaft NOTE Insert the cage with cut out portion facing the shaft end since the cage has an orientation DS 00283 A Cage B Cut out portion 5 I
40. strut assembly and then remove the rear spindle back plate and hub unit as a unit DS 00278 A Rear spindle B Strut ASSY B INSTALLATION 1 Combine the rear spindle assembly and strut as sembly Tightening torque 196 N m 20 kgf m 145 ft lb CAUTION Use a new self locking nut 2 Combine the rear spindle assembly and trailing link assembly Tightening torque 90 N m 9 2 kgf m 66 ft lb CAUTION Use a new self locking nut 3 Combine the rear spindle assembly and lateral link assembly Tightening torque 140 N m 14 3 kgf m 103 ft lb DS 33 Rear Axle FWD Model DRIVE SHAFT SYSTEM 4 Clean the brake pipe connection and then con nect the brake pipe to wheel cylinder using a flare nut wrench Tightening torque 15 N m 1 5 kgf m 10 8 ft Ib 5 Connect the cable end of parking brake cable Ref to PB 5 INSTALLATION Parking Brake Ca ble 6 Install the drum brake to rear spindle 7 Tighten the axle nut using a socket wrench of 32 mm then caulk the axle nut Tightening torque 200 N m 20 0 kgf m 145 ft Ib 8 Install the O ring to cap flange portion and then tap the hub cap by plastic hammer to install it CAUTION e Do not tap directly by copper hammer If O ring has scratches replace it with a new one If hub cap has deformed flange replace it 9 Install the wheel and wheel cap Tightening torque 90 N m 9 2 kgf m 66 ft Ib 10 Connect the battery ground cable to bat
41. t DRIVE SHAFT SYSTEM NOTE The grease is a special grease grease for con stant velocity joint Do not confuse with other greases Disassemble with exercising care not to lose balls 6 pcs DS 00126 A Outer race B Grease 8 To remove the cage from inner race turn the cage by a half pitch to the track groove of inner race and shift the cage 9 Remove the snap ring which fixes the inner race to shaft by using pliers 10 Take out the DOJ inner race 11 Take off the DOJ cage from shaft and remove the DOJ boot 12 Wrap the shaft splines with vinyl tape 13 Remove the BJ boot in the same procedure as DOJ boot NOTE Further disassembly of axle is impossible because the BJ cannot be disassembled D ASSEMBLY 1 EBJ PTJ TYPE NOTE Use specified grease EBJ side NTG2218 M Part No 28395AG010 PTJ side NSG301 Part No 28395AG020 1 Place the EBJ boot and small boot band on EBJ side of shaft CAUTION Be sure to wrap the shaft splines with vinyl tape to prevent the boot from scratches 2 Place the drive shaft in a vise CAUTION Do not place the drive shaft directly in a vise use wooden blocks 3 Apply a coat of specified grease 60 to 70 g 2 12 to 2 47 oz to EBJ 4 Apply an even coat of specified grease 20 to 30 g 0 71 to 1 06 oz to entire inner surface of boot Also apply grease to shaft NOTE EBJ installation surface of EBJ boot shall be cleaned so as
42. t the ground cable from battery 2 Lift up the vehicle and remove the rear wheel cap and wheels 3 Unlock the axle nut 4 Remove the axle nut using a socket wrench CAUTION Be sure to loosen and retighten the axle nut af ter removing the wheel from vehicle Failure to follow this rule may damage the wheel bear ings 5 Return the parking brake lever and loosen the adjusting nut PB 00005 1 Parking brake lever 2 Lock nut 3 Adjusting nut 6 Remove the brake drum from hub 7 If it is difficult to remove the brake drum remove the adjusting hole cover from back plate and then turn the adjusting screw using a flat tip screwdriver until the brake shoe separates from drum DS 00072 k Back plate Wheel cylinder Adjuster ASSY pawls Adjusting lever Tightening direction Push anann EZ MAR O BON E ie e E e aH Oo DS 26 Rear Axle AWD Model NOTE If the brake drum is difficult to remove drive it out by installing two 8 mm bolts into bolt hole in brake drum DS 00073 8 Remove the brake hose clamp from the rear strut portion and separate the brake hose BR 00126 1 Brake pipe 2 Brake hose 3 Brake hose clamp 9 Cover the open end of brake pipe with vinyl sheet or equivalent to prevent brake fluid from spill ing 10 Disconnect the parking brake cable end DS 00
43. tery 11 Bleed air from brake system Ref to BR 62 PROCEDURE Air Bleeding 12 Adjust the stroke of parking brake lever Ref to PB 4 ADJUSTMENT Parking Brake Lever C DISASSEMBLY CAUTION Disassembly the rear axle only when rattling dragging noise or etc are found on bearing 1 Remove the hub unit from rear spindle DS 00279 A Hub unit 2 Remove the drum brake assembly or parking brake assembly from rear spindle DS 00280 D ASSEMBLY 1 Completely remove away dust and foreign mate rial on polished surface and mounting surface of rear spindle to drum brake assembly 2 Install the drum brake assembly or parking brake assembly to rear spindle Tightening torque 53 N m 5 3 kgf m 39 1 ft Ib 3 Fill grease to oil seal at rear side of hub unit Grease Shell 6459N 4 Install the hub unit to rear spindle and hold them with washer and axle nut temporarily CAUTION Use a new axle nut E INSPECTION 1 Moving the rear tire up and down by hand check there is no backlash in bearing and check the wheel rotates smoothly DS 00061 2 Inspect the lean of axis direction using a dial gauge Replace the hub bearing if the load range exceeds the limitation DS 34 Rear Axle FWD Model DRIVE SHAFT SYSTEM Limit Maximum 0 05 mm 0 0020 in DS 00062 DS 35 Front Drive Shaft DRIVE SHAFT SYSTEM 6 Front Drive Shaft A REMOVA
44. ve the free ring from trunnion CAUTION Be careful with the free ring position 8 Place an alignment mark on trunnion and shaft DS 00110 DS 37 Front Drive Shaft DRIVE SHAFT SYSTEM 9 Remove the snap ring and trunnion DS 00209 CAUTION Be sure to wrap the shaft splines with vinyl tape to prevent the boot from scratches 10 Remove the PTJ boot 11 Place the drive shaft in a vise between wooden blocks CAUTION Do not place the drive shaft directly in a vise use wooden block 12 Raise the boot band claws by means of screw driver and hammer DS 00112 A Boot band claws 13 Cut and remove the boot CAUTION The boot must be replaced with a new one whenever it is removed DS 00113 NOTE Further disassembly of axle is impossible because the EBJ cannot be disassembled 2 BJ DOJ TYPE 1 Straighten the bent claw of larger end of DOJ boot 2 Loosen the band by means of screwdriver or pli ers with care of not damaging boot DS 00124 3 Remove the boot band on the small end of DOJ boot in the same manner 4 Remove the larger end of DOJ boot from DOJ outer race 5 Pry and remove the round circlip located at neck of DOJ outer race with a screwdriver DS 00125 6 Take out the DOJ outer race from shaft assem bly 7 Wipe off the grease and then take out the balls DS 38 Front Drive Shaf
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