Subaru Car 1998-05

CV-Joints

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Overhaul





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Fig. Removing the bands from the joint (1997)



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Fig. Remove the large circlip from the outer race (1997)



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Fig. Orientation of the CV-joint when assembled (1997)



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Fig. Remove the snapring to separate the joint (1997)



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Fig. Inner race and cage-align the cage with the protruding part of the inner race (1997)



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Fig. Install the inner race and ball assembly into the outer race (1997)



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Fig. Make sure the circlip is securely in the outer race, and not in the ball groove (1997)



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Fig. Install the CV-boot and band-make sure to pull the band snug (1997)



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Fig. Use a hammer to tap the band end down until it is snug-use care not to rip the boot (1997)

  1. Remove the bands from the boots at both the constant velocity and double offset joints, and slide the boots away from the joints.
  2.  
  3. Pry the circlip out of the double offset joint, and slide the outer race of the joint off the shaft.
  4.  
  5. Remove the balls from the cage, rotate the cage slightly, and slide the cage inward on the axle shaft.
  6.  
  7. Using snapring pliers, remove the outer snapring which retains the inner race to the shaft.
  8.  
  9. Slide the inner race, cage, and boot off the axle shaft.
    WARNING
    Exercise care to avoid damaging the boot on the inner snapring.

  10.  
  11. Pull back the constant velocity joint boot and pivot the stub axle around the joint far enough to expose a ball.
  12.  
  13. Remove the exposed ball, and continue this procedure until all balls are removed, at which time the outer race (stub axle) may be removed from the axle shaft.
  14.  
  15. Remove the retaining snapring, and slide the inner race off the shaft.
  16.  
  17. Inspect the parts of both joints for wear, damage, or corrosion, and replace if necessary. Examine the axle shaft for bending or distortion, and replace if evident. Should the boots be dried out, cracked, or distorted, they must be replaced.
  18.  
  19. Install the constant velocity joint inner race on the axle shaft, and retain with a snapring.
  20.  
  21. Assemble the joint in the opposite order of disassembly.
  22.  
  23. Slide the double offset joint cage onto the shaft, with the counterbore toward the end of the shaft.
  24.  
  25. Install the inner race on the shaft, and install the retaining snapring.
  26.  
  27. Position the cage over the inner race, and fill the cage pockets with grease.
  28.  
  29. Insert the balls into the cage.
  30.  
  31. Fill the well in the outer race with approximately 1 oz. grease, and slide the outer race onto the axle shaft.
  32.  
  33. Align the outer race track and ball positions and place it into the part where the shaft, inner cage and balls were previously installed, then install it into the outer race.
  34.  
  35. Install the retaining circlip in the grove on the outer race.
    NOTE
    Assure that the balls, cage and inner race are completely fitted in the outer race of the joint. Exercise care not to place the matched position of the circlip in the ball groove of the outer race. Finally, pull lightly on the shaft and assure that the circlip is completely fitted in the groove.

  36.  
  37. Add 1 oz. more grease to the interior of the joint. Fill the boot with approximately 1 oz. grease, and slide it into position over the double offset joint.
  38.  
  39. Fill the constant velocity joint boot with 3 oz. grease, and install the boot over the joint.
  40.  
  41. Band the boots on both joints tightly enough that they cannot be turned by hand.
    WARNING
    Use only grease specified for use in constant velocity joints.



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    Fig. Exploded view of the front halfshaft assembly with free-tripod joint-SVX shown

  42.  

  1. Place alignment marks on the shaft and outer race.
  2.  
  3. Remove the inner boot band and boot.
  4.  
  5. Remove the circlip from the inner joint outer race using a suitable prytool.
  6.  
  7. Outer race from the shaft assembly and wipe off the grease.
  8.  
  9. Place alignment marks on the free ring and trunnion as shown in the illustration.

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    Fig. Place alignment marks on the free ring and trunnion as shown-Front halfshaft (1998-2005)



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    Fig. Place alignment marks on the trunnion and shaft as shown-Front halfshaft (1998-2005)



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    Fig. Remove the snapring and trunnion-Front halfshaft (1998-2005)

  10.  
  11. Remove the free ring from the trunnion.
  12.  
  13. Place alignment marks on the trunnion and shaft as shown in the illustration.
  14.  
  15. Remove the snapring and trunnion.
  16.  
  17. Place the shaft in a vise between wooden blocks.
  18.  
  19. Using a suitable prytool, raise the outer boot band claws.
  20.  
  21. Cut and remove the boot.
  22.  
  23. Only the boot can be replaced, the joint is not serviceable and must be replaced if damaged.
  24.  

To install:

  1. Place the half shaft in a vise.
  2.  
  3. Place the outer boot and small band on the shaft.
  4.  
  5. Apply 2.12-2.47 oz. (60-70g) of supplied grease to the joint.
  6.  
  7. Apply 0.71-1.06 oz. (20-30g) of supplied grease to the whole inner surface of the boot, and apply some grease to the shaft.
  8.  
  9. Install the boot to the joint groove, and attach the large boot band as shown.
  10.  
  11. Install the boot to the shaft groove, and attach the small boot band as shown.

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    Fig. Position the boot to the joint groove, and attach the large boot band as shown-Front halfshaft (1998-2005)



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    Fig. Position the boot to the shaft groove, and attach the small boot band as shown-Front halfshaft (1998-2005)



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    Fig. Using boot band plier tool 28099A000 tighten the boot bands-Front halfshaft (1998-2005)

  12.  
  13. Using boot band plier tool 28099A000 to tighten the large band to 116 ft. lbs. (157 Nm) and the small band to 98 ft. lbs. (133 Nm).
  14.  
  15. Place the inner boot on the center of the shaft.
  16.  
  17. Align the alignment marks from earlier and install the trunnion and snapring. Make sure the snapring is fully engaged.
  18.  
  19. Apply 3.53-3.88 oz. (100-110g) of supplied grease to the joint outer race.
  20.  
  21. Apply a coat of supplied grease to the free ring and trunnion.
  22.  
  23. Align the marks on the free ring and trunnion and install the free ring.
  24.  
  25. Align the marks on the shaft and outer race and install the outer race.
  26.  
  27. Pull on the shaft lightly to ensure the circlip is completely engaged.
  28.  
  29. Apply an even coat 1.06-1.41 oz. (30-40g) of the supplied grease to the entire inner surface of the boot.
  30.  
  31. Install the boot and band.
  32.  
  33. Once the band is properly tightened, cut off any excess to leave only 0.39 inch (10mm) and bend it over.
  34.  
  35. Install the shaft.
  36.  

 
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