Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 516
DS-37
Rear Drive Shaft
DRIVE SHAFT SYSTEM
C: DISASSEMBLY
1. EXCEPT FOR STI MODEL
1) Using a flat tip screwdriver or plier, loosen the
boot band on the large end of DOJ boot.
CAUTION:
Be careful not to damage the boot.
2) Remove the boot band on the small end of DOJ
boot in the same manner.
3) Remove the large end of DOJ boot from DOJ
outer race.
4) Remove the round snap ring at the neck of DOJ
outer race with a flat tip screwdriver.
5) Take out the DOJ outer race from the shaft as-
sembly.
6) Wipe off the grease and take out the ball bear-
ings.
CAUTION:
The grease is a special grease (grease for con-
stant velocity joints). Do not mix with other
greases.
NOTE:
Disassemble exercising care not to lose balls.
7) 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.
8) Using pliers, remove the snap ring fixing the in-
ner race to the shaft.
9) Take out the DOJ inner race.
10) Take off the DOJ cage from shaft and remove
the DOJ boot.
CAUTION:
Wrap shaft splines with vinyl tape to protect the
boot from scratches.
11) Remove the EBJ boot using the same proce-
dures as for the DOJ boot.
NOTE:
The EBJ is a non-disassembly part, so the drive
shaft disassembly stops here.
DS-00124
DS-00125
(A) Outer race
(B) Grease
DS-00126
(B)
(A)
DS-38
Rear Drive Shaft
DRIVE SHAFT SYSTEM
2. STI MODEL
1) Using a flat tip screwdriver or plier, loosen the
boot band on the large end of EDJ boot.
CAUTION:
Be careful not to damage the boot.
2) Remove the boot band on the small end of EDJ
boot in the same manner.
3) Remove the large end of EDJ boot from EDJ
outer race.
4) Remove the round snap ring at the neck of EDJ
outer race with a flat tip screwdriver.
5) Remove the EDJ outer race from shaft assem-
bly.
6) Wipe off the grease and take out the ball bear-
ings.
CAUTION:
The grease is a special grease (grease for con-
stant velocity joints). Do not mix with other
greases.
NOTE:
Disassemble exercising care not to lose balls.
7) 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.
8) Using pliers, remove the snap ring fixing the in-
ner race to the shaft.
9) Take out the EDJ inner race.
10) Take off the EDJ cage from shaft and remove
the EDJ boot.
CAUTION:
Wrap shaft splines with vinyl tape to protect the
boot from scratches.
11) Remove the EBJ boot using the same proce-
dures as for the EDJ boot.
NOTE:
The EBJ is a non-disassembly part, so the drive
shaft disassembly stops here.
DS-00124
DS-00125
(A) Outer race
(B) Grease
DS-00126
(B)
(A)
DS-39
Rear Drive Shaft
DRIVE SHAFT SYSTEM
D: ASSEMBLY
1. STI MODEL
CAUTION:
Wrap shaft splines with vinyl tape to protect the
boot from scratches.
NOTE:
Use specified grease.
EBJ side:
NKG814
EDJ side:
NKG814
1) Install the EBJ boot to the specified position, and
fill it with 50 to 60 g (1.76 to 2.12 oz) of specified
grease.
2) Place the EDJ boot at the center of shaft.
3) Insert the EDJ cage onto shaft.
NOTE:
Insert the cage with the cutout portion facing the
shaft end, since the cage has an orientation.
4) Install the EDJ inner race on shaft and fix the
snap ring in place with pliers.
NOTE:
Confirm that the snap ring is completely fitted in the
shaft groove.
5) Install the cage to inner race fixed upon shaft.
NOTE:
Fit the cage with the protruding section aligned with
the track on the inner race, and turn by a half pitch.
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
grease into the inner side of the EDJ outer race.
7) Apply a thin coat of specified grease to the cage
pocket and ball.
8) Insert the ball bearings into the cage pocket.
9) Align the outer race track and ball positions, and
place the shaft, inner race, cage and ball bearings
in the original positions, and then fix outer race in
place.
(A) Cage
(B) Cutout portion
DS-00395
(B)
(A)
DS-00128
(A) Inner race
(B) Cage
(A) Outer race
(B) Grease
DS-00129
(B)
(A)
DS-00126
(B)
(A)
DS-40
Rear Drive Shaft
DRIVE SHAFT SYSTEM
10) Install the snap ring in the groove on the EDJ
outer race.
NOTE:
• Assure that the balls, cage and inner race are
completely fitted in the outer race of EDJ.
• Use care not to place the matched position of
snap ring in the ball groove of outer race.
• 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 the shaft.
12) Install the EDJ boot taking care not to twist it.
NOTE:
• The inside of the large end of EDJ boot and the
boot groove shall be cleaned so as to be free from
grease and other substances.
• When installing the EDJ boot, position the outer
race of EDJ at center of the stroke.
13) Put a new band through the clip and wind twice
in the band groove of the boot.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening boot, use care so that the air with-
in the 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.
16) Tap the clip with the punch provided at the end
of the ST.
ST 925091000
BAND TIGHTENING TOOL
NOTE:
Tap to an extent that the boot underneath is not
damaged.
17) Cut off the band with an allowance of about 10
mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
NOTE:
Be careful so that the end of the band is in close
contact with clip.
18) Install the EBJ boot using the same procedures
as for the EDJ boot.
19) Extend and retract the EDJ repeatedly to pro-
vide an equal coating of grease.
DS-00125
DS-00132
DS-00133
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