Subaru Legacy III (2000-2003 year). Manual - part 688

DS-30

DRIVE SHAFT SYSTEM

FRONT DRIVE SHAFT

9) Remove snap ring and trunnion.

CAUTION:
Be sure to wrap shaft splines with vinyl tape to 
prevent boot from  scratches.
10) Remove SFJ boot.
11) Place drive shaft in a vise between wooden
blocks.

CAUTION:
Do not place drive shaft directly in the vise; use 
wooden block.
12) Raise boot band claws by means of screwdriv-
er and hammer.

13) Cut and remove the boot.

CAUTION:
The boot must be replaced with a new one 
whenever it is removed.

14) Disassembly of axle is completed at steps
above because BJ cannot be disassembled.

(A) Boot band claws

DS-00111

DS-00112

( A )

( A )

DS-00113

DS-31

DRIVE SHAFT SYSTEM

FRONT DRIVE SHAFT

D: ASSEMBLY

CAUTION:
Use specified grease.

BJ side:

NTG2218 (Part No. 28093AA000)

SFJ side:

SSG6003 (Part No. 28093TA000)

1) Place BJ boot and small boot band on BJ side of
shaft.

CAUTION:
Be sure to wrap shaft splines with vinyl tape to 
prevent boot from  scratches.
2) Place drive shaft in a vise.

CAUTION:
Do not place drive shaft directly in the vise; use 
wooden blocks.
3) Apply a coat of specified grease [60 to 70 g (2.12
to 2.47  oz)] to BJ.
4) Apply an even coat of specified grease [20 to 30
g (0.71 to  1.06 oz)] to the entire inner surface of
boot. Also apply grease to  shaft.

NOTE:
The inside of the larger end of BJ boot and the boot
groove shall be  cleaned so as to be free from
grease and other substances.
5) Install boot projecting portion to BJ groove.

6) Set large boot band in place.

7) Install boot projecting portion to shaft groove.

8) Tighten boot bands using ST, torque wrench and
socket flex  handle.
ST

28099AC000

BOOT BAND PLIER

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-lb) or more

9) Place SFJ boot at the center of shaft.
10) Align alignment marks and install trunnion on
shaft.

(A) BJ

(B) Large boot band

(C) Boot

DS-00114

( A )

( B )

( C )

(A) Boot

(B) Small boot band

(C) Shaft

(A) Large boot band

(B) Boot

(C) Torque wrench

(D) Socket flex handle

(E) BJ

DS-00115

( A )

( B )

( C )

DS-00116

( A )

( B )

( C )

( D )

( E )

ST

DS-00110

DS-32

DRIVE SHAFT SYSTEM

FRONT DRIVE SHAFT

11) Install snap ring to shaft.

CAUTION:
Confirm that the snap ring is completely fitted 
in the shaft groove.
12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
grease into the  interior of SFJ outer race.
13) Apply a coat of specified grease to free ring and
trunnion.
14) Align alignment marks on free ring and trunnion
and install free  ring.

CAUTION:
Be careful with the free ring position.

15) Align alignment marks on shaft and outer race,
and install outer  race.

16) Install circlip in the groove on SFJ outer race.

CAUTION:
Pull the shaft lightly and assure that the circlip 
is completely fitted  in the 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 SFJ boot taking care not to twist it.

CAUTION:
• The inside of the larger end of SFJ boot and
the boot groove  shall be cleaned so as to be
free from grease and other substances.
• When installing SFJ boot, position outer race
of SFJ at center of  its travel.
19) Put a band through the clip and wind twice in
alignment with  band groove of boot.

CAUTION:
Use a new band.
20) Pinch the end of band with pliers. Hold the clip
and tighten  securely.

NOTE:
When tightening boot, exercise care so that the air
within the boot is  appropriate.
21) Tighten band by using ST.
ST

925091000

BAND TIGHTENING TOOL

NOTE:
Tighten band until it cannot be moved by hand.

22) Tap on the clip with the punch provided at the
end of ST.
ST

925091000

BAND TIGHTENING TOOL

CAUTION:
Tap to an extent that the boot underneath is not 
damaged.

DS-00109

DS-00158

DS-00132

DS-00133

DS-33

DRIVE SHAFT SYSTEM

FRONT DRIVE SHAFT

23) Cut off band with an allowance of about 10 mm
(0.39 in) left  from the clip and bend this allowance
over the clip.

CAUTION:
Be careful so that the end of the band is in close 
contact with clip.
24) Fix up boot on BJ in the same manner.

NOTE:
Extend and retract SFJ to provide equal grease
coating.

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) SFJ (Shudder-less Free-ring tripod Joint)
Check seizure, corrosion, damage and excessive
play.
3) Shaft
Check excessive bending, twisting, damage and
wear.
4) BJ (Bell Joint)
Check seizure, corrosion, damage and excessive
play.
5) Boot
Check for wear, warping, breakage or scratches.
6) Grease
Check for discoloration or fluidity.