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    Subaru Car 1998-05

    Halfshaft

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    Removal & Installation



    1997 Models
    Impreza & Legacy 2wd


    Click image to see an enlarged view

    Fig. View of the rear spindle and lateral links-2WD Impreza and Legacy (1997)



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    Fig. View of the trailing link and its retaining bolt (1997)



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    Fig. View of the rear spindle and strut assembly (1997)



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    Fig. View of the removed hub unit and backing plate (1997)



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    Fig. Exploded view of the axle and hub assembly-2WD Impreza and Legacy (1997)

    1. Disconnect the negative battery cable.
    2.  
    3. Raise the vehicle and support safely.
    4.  
    5. Remove the wheels and unlock the axle nut. Remove the axle nut.
    6.  
    7. Loosen the parking brake adjuster. Remove the disc brake assembly from the backing plate and suspend it with a wire from the strut.
    8.  
    9. Remove the disc brake rotor from the hub and disconnect the end of the parking brake cable.
    10.  
    11. Remove the bolts that retain the lateral link, trailing link and the strut to the rear spindle.
    12.  
    13. Remove the rear spindle, backing plate and hub as a unit.
    14.  
    15. The installation is the reverse of the removal procedure. Use the following values during installation.
      1. Rear spindle to strut assembly-98-119 ft. lbs. (133-161 Nm).
      2.  
      3. Rear spindle assembly to trailing link-72-94 ft. lbs. (98-127 Nm).
      4.  
      5. Rear spindle to lateral link-87-116 ft. lbs. (118-157 Nm).
      6.  
      7. Disc brake assembly to backing plate-34-43 ft. lbs. (46-58 Nm).
      8.  
      9. Axle nut-123-152 ft. lbs. (167-206 Nm).
      10.  
      11. Wheel nuts-58-72 ft. lbs. (79-98 Nm).
      12.  

    16.  

    Impreza & Legacy 4wd


    Click image to see an enlarged view

    Fig. View of the lateral links and their fasteners-4WD Impreza and Legacy (1997)



    Click image to see an enlarged view

    Fig. View of the trailing link and its retaining bolt (1997)



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    Fig. Removal or installation of the axle spring pin (1997)



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    Fig. Pressing the axle shaft from the bearing housing (1997)



    Click image to see an enlarged view

    Fig. Exploded view of the rear axle and hub assembly-4WD Impreza and Legacy (1997)

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Unstake and remove the axle nut.
    6.  
    7. Remove the sway bar bracket.
    8.  
    9. Remove the lower control arm-to-rear housing bolt and nut.
    10.  
    11. Remove the trailing link assembly-to-rear housing bolt and nut.
    12.  
    13. Remove the halfshaft-to-differential roll pin.
    14.  
    15. Disconnect the halfshaft from the differential.
    16.  
    17. Using puller 92707000 or equivalent, remove the halfshaft from the hub.
    18.  

    To install:

    1. Insert the halfshaft into the hub.
    2.  
    3. Using installer 922431000 and adapter 927390000 or equivalent, pull the halfshaft into place.
    4.  
    5. Install and temporarily tighten a new axle nut.
    6.  
    7. Align the halfshaft-to-differential roll pin holes and slide the halfshaft onto the splines. Install a new roll pin.
    8.  
    9. Connect the trailing link assembly to the rear housing. Install the bolt and new nut and tighten them to 94 ft. lbs. (127 Nm). Install all remaining components in the reverse order of removal.
    10.  

    SVX


    Click image to see an enlarged view

    Fig. Exploded view of the rear axle and hub assembly-SVX

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Remove the tire and wheel assembly.
    6.  
    7. Unstake and remove the axle nut.
    8.  
    9. Move the parking brake lever forward.
    10.  
    11. Disconnect the rear exhaust pipe.
    12.  
    13. Remove the sway bar link.
    14.  
    15. Remove the ABS sensor clamp and parking brake cable bracket from the trailing link.
    16.  
    17. Remove the parking brake cable from the floor.
    18.  
    19. Disconnect the brake hose from the strut.
    20.  
    21. Remove the trailing link-to-knuckle through-bolt and nut.
    22.  
    23. Remove the lateral link-to-knuckle through-bolt and nut.
    24.  
    25. Disconnect the halfshaft from the differential carrier using a half shaft remover, 28099PA100, or the equivalent.
    26.  
    27. Remove the halfshaft from the rear bearing assembly.
    28.  

    To install:

    1. Install a new circlip on the inboard end of the halfshaft.
    2.  
    3. Insert the outer joint through the hub splines. Using a halfshaft installer, pull the shaft into the hub completely.
    4.  
    5. Install the inboard joint into the differential carrier.
    6.  
    7. Once the splines are lined up the inner joint can be seated fully by pushing in on the knuckle.
    8.  
    9. Line up the lateral links and install the through-bolt and nut and tighten to 86 ft. lbs. (118 Nm).
    10.  
    11. Line up the trailing link and install the through-bolt and nut and tighten to 90 ft. lbs. (123 Nm).
    12.  
    13. The remaining of installation is the reverse of removal. Secure all components accordingly.
    14.  
    15. Install the axle nut and tighten to 138 ft. lbs. (186 Nm).
    16.  
    17. Check the front end alignment and adjust as necessary.
    18.  

    1998-2004 Models
    Except Impreza
    1. Remove or disconnect the following:

      Negative battery cable
       
      Wheel
       
      Axle nut, unstake the nut before attempting removal
       

    2.  
    3. Remove the rear differential on vehicles equipped with a T-type as follows:
      1. Place the gear shifter into the Neutral position.
      2.  
      3. Release the parking brake.
      4.  
      5. Remove the rear exhaust pipe and muffler.
      6.  
      7. Remove the heat shield cover.
      8.  
      9. Remove the driveshaft (propeller).
      10.  
      11. Remove the rear differential protector, if equipped.
      12.  
      13. Place a transmission jack under the differential and loose the nuts that attach the differential to the rear crossmember.
      14.  
      15. Remove the driveshaft joint from the differential using a suitable shaft removal tool such as ST 28099PA100.
      16.  
      17. Remove the protector nut.
      18.  
      19. Remove the differential front member and support the differential assembly with the transmission jack making sure to securely attach the differential to the jack with a chain or strap.
      20.  
      21. Remove the nuts attaching the differential to the crossmember.
      22.  
      23. Remove the differential stud bolt from the rear crossmember bushing. You may have to carefully adjust the angle and position of the jack to facilitate stud removal.
      24.  
      25. Once the stud bolt has been removed, lower the jack, making sure the rear drive shaft does not strike the lateral link bolt.
      26.  
      27. Pull the driveshaft out of the differential and remove the differential.
      28.  

    4.  
    5. Remove the rear differential on vehicles equipped with a VA-type as follows:
      1. Place the gear shifter into the Neutral position.
      2.  
      3. Release the parking brake.
      4.  
      5. Remove the rear exhaust pipe and muffler.
      6.  
      7. Remove the heat shield cover.
      8.  
      9. Remove the driveshaft (propeller).
      10.  
      11. Place a transmission jack under the differential and loosen the nuts that attach the differential to the rear crossmember.
      12.  
      13. Remove the driveshaft joint from the differential using a suitable shaft removal tool such as ST 28099PA100.
      14.  
      15. Remove the protector nut.
      16.  
      17. Remove the nuts with attach the differential to the front member. Support the differential assembly with the transmission jack.
      18.  
      19. Remove the differential front member and securely attach the differential to the jack with a chain or strap.
      20.  
      21. Remove the nuts attaching the differential to the crossmember.
      22.  
      23. Remove the differential stud bolt from the rear crossmember bushing. You may have to carefully adjust the angle and position of the jack to facilitate stud removal.
      24.  
      25. Once the stud bolt has been removed, lower the jack, making sure the rear drive shaft does not strike the lateral link bolt.
      26.  
      27. Pull the driveshaft out of the differential and remove the differential.
      28.  

    6.  
    7. Remove the axle nut and using a suitable puller, remove the halfshaft from the being careful not to damage the tone wheel using puller ST 926470000 and plate ST 927140000.
    8.  

    To install:

    1. Insert the axle into the hub splines being careful not to damage the tone wheel using adapter installer ST1 922431000 and adapter ST2 927390000. Tighten the axle nut until snug.
    2.  
    3. Install the rear differential on vehicles equipped with a VA-type as follows:
      1. Place the differential on a transmission jack and fasten securely with a chain or band.
      2.  
      3. Place a seal protector tool such as ST28099PA090 on the differential.
      4.  
      5. Insert the splined shaft of the halfshaft until the spline portion is inside the oil seal.
      6.  
      7. Remove the seal protector.
      8.  
      9. Insert the driveshaft into the differential until it is fully seated.
      10.  
      11. Adjust the transmission jack as necessary so the stud bolt is inserted correctly into the crossmember bushing.
      12.  
      13. Once the stud bolt is inserted, raise the transmission jack until the differential is level.
      14.  
      15. Temporarily tighten the rear crossmember nuts.
      16.  
      17. Remove the band or chain securing the differential to the transmission jack and raise the differential enough to move the jack away. Install the differential member and two inner bolts to 81 ft. lbs. (110 Nm) and the outer bolt to 48 ft. lbs. (65 Nm).
      18.  
      19. Tighten the crossmember self locking nut to 51 ft. lbs. (70 Nm) and the protector nut to 47 ft. lbs. (64 Nm).
      20.  
      21. Remove the jack and install the driveshaft (propeller).
      22.  
      23. Install the heat shield cover.
      24.  
      25. Install the rear exhaust pipe and muffler.
      26.  
      27. Apply the parking brake.
      28.  
      29. Place the gear shifter into the Park position.
      30.  

    4.  
    5. Remove the filler plug and fill the differential to the level. Tighten the filler plug to 25 ft. lbs. (34 Nm).
    6.  
    7. Install the rear differential on vehicles equipped with a T-type as follows:
      1. Place the differential on a transmission jack and fasten securely with a chain or band.
      2.  
      3. Place seal protector tool ST 28099PA090 over the differential side oil seal and insert the shaft until the spline portion is inside the seal. Remove the seal protector.
      4.  
      5. Insert the axle shaft completely into the differential
      6.  
      7. Adjust the transmission jack as necessary so the stud bolt is inserted correctly into the crossmember bushing.
      8.  
      9. Once the stud bolt is inserted, raise the transmission jack until the differential is level.
      10.  
      11. Temporarily tighten the rear crossmember nuts .
      12.  
      13. Remove the band or chain securing the differential to the transmission jack and raise the differential enough to move the jack away. Install the differential member and tighten the T1 bolts to 48 ft. lbs. (65 Nm) and the T2 bolt to 81 ft. lbs. (110 Nm).
      14.  
      15. Tighten the rear crossmember self locking nut to 51 ft. lbs. (70 Nm) and the protector nut to 47 ft. lbs. (64 Nm).
      16.  
      17. Remove the jack and install the driveshaft (propeller).
      18.  
      19. Install the heat shield cover.
      20.  
      21. Install the rear exhaust pipe and muffler.
      22.  
      23. Apply the parking brake.
      24.  
      25. Place the gear shifter into the Park position.
      26.  

    8.  
    9. Remove the filler plug and fill the differential to the level. Tighten the filler plug to 36 ft. lbs. (49 Nm).
    10.  
    11. Install or connect the following:

      Axle nut and tighten to 174 ft. lbs. (235 Nm). Stake the nut.
       
      Wheels
       
      Negative battery cable
       

    12.  
    13. Check all fluids and road test the vehicle.

      Click image to see an enlarged view

      Fig. Place seal protector tool ST 28099PA090 over the rear differential side oil seal-2002-2004 Legacy, Outback and Baja



      Click image to see an enlarged view

      Fig. Tighten the rear differential front member and tighten the T1 and T2 bolts to the specifications-2002-2004 Legacy, Outback and Baja



      Click image to see an enlarged view

      Fig. Install the rear axle into the hub splines using adapter installer ST1 922431000 and adapter ST2 927390000-2002-2004 Legacy, Outback and Baja



      Click image to see an enlarged view

      Fig. Location of the rear differential drain and fill plugs-2002-2004 Legacy, Outback and Baja

    14.  

    Impreza
    1. Remove or disconnect the following:
      NOTE
      The side spline shaft circlip comes out with the shaft.


      CAUTION
      Be careful not to damage the side bearing retainer use the bolt at the 5 O-clock position as a supporting point when using the removal tool.



      Negative battery cable
       
      Axle nut
       
      Wheels
       
      Halfshaft from the differential using remover tool ST 28099PA100
       



      Axle shaft from the hub using puller ST 9266470000 and puller plate 927140000
       

    2.  

    To install:

    1. Install the axle shaft into the hub. Use installer ST 922431000 and adapter ST 927390000 to pull the drive shaft into place and side tighten the axle nut.
    2.  
    3. Place a seal protector tool such as ST28099PA090 on the differential.
    4.  
    5. Insert the splined shaft of the halfshaft until the spline portion is inside the oil seal.
    6.  
    7. Remove the seal protector.
    8.  
    9. Insert the driveshaft into the differential until it is fully seated.
    10.  
    11. Insert the splined shaft of the halfshaft until the spline portion is inside the oil seal.
    12.  
    13. Torque the new axle nut to 137 ft. lbs. (186 Nm) on 2002 vehicles or 174 ft. lbs. (235 Nm) on 2002-2003 vehicles and stake the nut.

      Wheel
       
      Negative battery cable
       

    14.  

    2005 Models
    Baja


    Click image to see an enlarged view

    Fig. Rear halfshaft and related components-2005 Baja

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Remove the wheels and tires.
    6.  
    7. Unlock the axle nut. Depress the parking brake. Remove the axle nut.
      NOTE
      Be sure to loosen and retighten the axle nut after removing the tire and wheel assembly from the vehicle. Failure to follow this rule may damage the wheel bearings.

    8.  
    9. Remove the rear differential assembly.
    10.  
    11. Remove the axle nut and rear halfshaft.
      NOTE
      Use axle shaft puller tools ST92647000 and ST28099PA110, or equivalent, if it is difficult to remove the halfshaft. Do not hammer the halfshaft to remove it. Be careful not to damage the oil seal or magnetic encoder.

    12.  

    To install:

    1. Installation is the reverse of the removal procedure.
    2.  
    3. Tighten the axle nut to 177 ft. lbs. with the parking brake applied.
      NOTE
      Install the tire and wheel assembly after installation of the axle nut. Failure to follow this order, may cause damage to the wheel bearings.

    4.  

    Impreza & WRX


    Click image to see an enlarged view

    Fig. Rear halfshaft and related components-2005 Impreza and WRX

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Remove the wheels and tires.
    6.  
    7. Unlock the axle nut. Depress the parking brake. Remove the axle nut.
      NOTE
      Remove the axle nut with vehicle weight NOT applied to the axle.

    8.  
    9. Disconnect the stabilizer link. Remove the bolt that retains the trailing link to the housing.
    10.  
    11. Remove the bolts which secure the front lateral link and rear lateral link to the housing.
    12.  
    13. Remove the ABS wheel speed sensor from the back plate.
    14.  
    15. Remove the halfshaft from the rear axle. If it is hard to remove, remove the brake disk rotor.
      NOTE
      Use axle shaft puller tools ST92647000 and ST28099PA110, or equivalent, if it is difficult to remove the halfshaft. Do not hammer the halfshaft to remove it. Be careful not to damage the oil seal or wheel tone.

    16.  
    17. Remove the halfshaft from the differential using tool ST28099PA100.
      NOTE
      Using the tool will prevent damage to the side bearing retainer.

    18.  

    To install:

    1. Installation is the reverse of the removal procedure.
    2.  
    3. Tighten the axle nut to 140 ft. lbs. with the parking brake applied.
    4.  

    Legacy & Outback


    Click image to see an enlarged view

    Fig. Rear halfshaft and related components-2005 Legacy and Outback

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Remove the wheels and tires.
    6.  
    7. Unlock the axle nut. Depress the parking brake. Remove the axle nut.
      NOTE
      Be sure to loosen the axle nut after removing the tire and wheel from the vehicle. Failure to do this may damage the wheel bearings.

    8.  
    9. Remove the rear differential assembly.
    10.  
    11. Remove the axle nut and rear halfshaft.
      NOTE
      Use axle shaft puller tools ST92647000 and ST28099PA110, or equivalent, if it is difficult to remove the halfshaft. Do not hammer the halfshaft to remove it. Be careful not to damage the oil seal or magnetic encoder.

    12.  

    To install:

    1. Installation is the reverse of the removal procedure.
    2.  
    3. Tighten the axle nut to 177 ft. lbs. with the parking brake applied.
      NOTE
      Install the tire and wheel assembly after installation of the axle nut. Failure to follow this order, may cause damage to the wheel bearings.

    4.  

     
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