Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Front Halfshafts

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REMOVAL & INSTALLATION



Justy

See Figures 1 through 14

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Fig. Fig. 1: View of the halfshaft and front hub assemblies



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Fig. Fig. 2: Suspend the brake caliper out of the way



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Fig. Fig. 3: Removing the center piece



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Fig. Fig. 4: Drive the spring pin from the halfshaft



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Fig. Fig. 5: Separating the ball joint from the transverse link



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Fig. Fig. 6: Removing the spindle housing from the strut



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Fig. Fig. 7: Using a special tool to separate the halfshaft from the spindle housing



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Fig. Fig. 8: Pressing the axle shaft into the spindle housing



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Fig. Fig. 9: Final pressing of the axle to the housing



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Fig. Fig. 10: Driving the spring pin into the double offset joint and differential shaft



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Fig. Fig. 11: Tightening the transverse link and housing pinch bolt



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Fig. Fig. 12: Tightening the tie rod ball joint-to-knuckle nut



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Fig. Fig. 13: Be sure to install the conical spring with the OUT side facing away from the bearing



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Fig. Fig. 14: Correct cotter pin installation

  1. Remove the wheel cover, cotter pin and loosen the castle nut.
  2.  
  3. Raise and support the vehicle safely. Remove the tire and wheel assembly.
  4.  
  5. Remove the disc brake assembly.
  6.  
  7. Remove the castle nut and conical spring. Remove the center piece, using the proper tools.
  8.  
  9. Pull the hub and disc assembly from the halfshaft (a special puller tool is not required). Remove the disc cover from the housing.
  10.  
  11. Drive out the spring pin connecting the halfshaft to the differential, using the proper tool.
  12.  
  13. Remove the cotter pin and the castle nut from the tie rod end ball joint.
  14.  
  15. Remove the tie rod end ball joint from the knuckle arm, using the proper puller.
  16.  
  17. Remove the bolt that retains the housing to the strut. Carefully push down the housing in order to remove it from the strut.
  18.  
  19. Remove the ball joint of the transverse link from the housing. Remove the housing and the halfshaft assembly as a complete unit.
  20.  
  21. Separate the housing from the halfshaft, using removal tools 922493000 and 921122000 or their equivalents.
  22.  

To install:
  1. Secure the spindle housing into a vice.
  2.  
  3. Install the axle into the housing. Using installation tool 927210000 or equivalent, press fit the axle until it contacts the housing flange.
  4.  
  5. When the installer tool begins to rotate, hold the body with a 1.61 in. (41mm) wrench and turn the handle to further press the axle shaft.
  6.  
  7. Install housing and axle assembly to strut but do not tighten.
  8.  
  9. Install the dust seal on the spindle. Insert the halfshaft into the differential and install a new spring pin. Lubricate the splines with grease.
  10.  
  11. Install the transverse link ball joint to the housing and tighten the nut to 25-33 ft. lbs. (34-44 Nm).
  12.  
  13. Connect the tie rod end ball joint to the knuckle arm an tighten the castle nut to 18-22 ft. lbs. (25-29 Nm). Turn the nut just enough to align the next nut slot and hole. Use a new cotter pin.
  14.  
  15. Tighten the housing-to-strut bolt to 25-33 ft. lbs. (34-44 Nm).
  16.  
  17. Install the disc cover, hub, disc brake assembly and castle nut. Do not tighten at this time.
  18.  
  19. Install the caliper assembly. Tighten bolts to 31-46 ft. lbs. (42-62 Nm).
  20.  
  21. Install the wheel and tire, lower the vehicle. Tighten the castle nut to 130 ft. lbs. (177 Nm) for 1987-88 vehicles or 145 ft. lbs. (196 Nm) for 1989 and later vehicles.
  22.  

Loyale, STD. and XT
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the parking brake cable bracket from the lower control arm.
  8.  
  9. Drive out the spring pin from the inner CV-joint.
  10.  
  11. Remove the caliper assembly and mounting bracket. Suspend the caliper assembly from a wire. DO NOT allow the caliper to hang from the brake hose.
  12.  
  13. Remove the brake rotor.
  14.  
  15. Remove the lower ball joint pinch bolt.
  16.  
  17. Remove the tie rod end cotter pin and castle nut and separate tie rod end from the steering knuckle.
  18.  
  19. Remove the strut-to-steering knuckle bolts.
  20.  
  21. Remove the steering knuckle and halfshaft as an assembly.
  22.  
  23. Using tool 926470000 or equivalent, press the axle shaft out of the bearing assembly.
  24.  

To install:
  1. Install the halfshaft through the hub bearing. Using installer tool 925130000 or equivalent, pull the shaft into place.
  2.  
  3. Install the axle and spindle assembly into the vehicle, guiding the halfshaft onto the splined shaft so the spring pin holes are in alignment. Install the lower ball joint stud into the lower control arm. Tighten the castle nut to 25 ft. lbs. (34 Nm) for all except XT6. For XT6, tighten to 69-83 ft. lbs. (93-113 Nm).
  4.  
  5. Install a new spring pin to secure the axle.
  6.  
  7. Connect the strut to the steering knuckle and install the two mounting bolts and tighten to 25 ft. lbs. (34 Nm).
  8.  
  9. Connect the tie rod end to the steering knuckle and tighten the castle nut to 20 ft. lbs. (27 Nm). Install a new cotter pin.
  10.  
  11. Install the brake rotor.
  12.  
  13. Install the caliper assembly onto the steering knuckle and tighten the mounting bracket-to-steering knuckle bolts to 44 ft. lbs. (59 Nm).
  14.  
  15. Connect the parking brake cable to the caliper.
  16.  
  17. Install the center piece, washer and castle nut on the axle and tighten the castle nut to 145 ft. lbs. (196 Nm).
  18.  
  19. Install the tire and wheel assemblies.
  20.  
  21. Lower the vehicle.
  22.  
  23. Connect the negative battery cable.
  24.  

Impreza and Legacy

See Figures 15 through 27

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Fig. Fig. 15: Unstaking the axle nut



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Fig. Fig. 16: Remove the transverse link arm from the crossmember



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Fig. Fig. 17: Drive out the halfshaft-to-transaxle roll pin



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Fig. Fig. 18: Remove the sway bar bracket



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Fig. Fig. 19: Using a special puller tool, press the axle shaft from the spindle housing



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Fig. Fig. 20: Use 2, 8mm bolts to loosen the rotor from the spindle housing



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Fig. Fig. 21: Using a special tool to separate the tie rod ball joint



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Fig. Fig. 22: Remove the transverse link arm from the spindle housing



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Fig. Fig. 23: Before loosening the strut-to-housing bolts scribe and mark on the camber adjustment bolt and strut



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Fig. Fig. 24: Be sure to identify the correct drive axle



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Fig. Fig. 25: Removing the ABS sensor



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Fig. Fig. 26: Tightening the axle nut



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Fig. Fig. 27: Staking the axle nut

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the wheel.
  6.  
  7. Unstake and remove the axle nut.
  8.  
  9. Remove the transverse link arm from the front crossmember.
  10.  
  11. Remove the halfshaft-to-transaxle roll pin and discard it.
  12.  
  13. Remove the sway bar bracket.
  14.  
  15. Disconnect the halfshaft from the transaxle.
  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 through the hub.
  4.  
  5. Install and temporarily tighten a new axle nut.
  6.  
  7. Align the halfshaft roll pin hole and insert the halfshaft onto the transaxle. Install a new roll pin.
  8.  
  9. Connect the lower control arm to the crossmember and tighten a new self-locking nut to 83 ft. lbs. (113 Nm).
  10.  
  11. Install the sway bar bracket.
  12.  
  13. Torque the new axle nut to 152 ft. lbs. (206 Nm) and stake the nut.
  14.  
  15. Install the wheel.
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the negative battery cable.
  20.  

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. Disconnect the sway bar link from the sway bar.
  10.  
  11. Disconnect the ABS sensor bracket from the strut.
  12.  
  13. Remove the brake hose bracket bolt and bracket from the strut.
  14.  
  15. Matchmark the sway bar lever to the sway bar. Remove the sway bar lever.
  16.  
  17. Loosen the sway bar bracket.
  18.  
  19. Remove the lower ball joint pinch bolt.
  20.  
  21. Drive out the spring pin securing the halfshaft to the transaxle. Discard the spring pin.
  22.  
  23. Separate the ball joint from the steering knuckle.
  24.  
  25. Disconnect the halfshaft from the transaxle.
  26.  
  27. Remove the halfshaft from the vehicle.
  28.  

To install:
  1. Install the halfshaft into the steering knuckle.
  2.  
  3. Connect the inboard end on the halfshaft to the transaxle. Make sure the spring pin holes line up.
  4.  
  5. Install a new spring pin.
  6.  
  7. Connect the ball joint to the steering knuckle.
  8.  
  9. Tighten the ball joint pinch bolt to 38 ft. lbs. (52 Nm).
  10.  
  11. Tighten the sway bar bracket.
  12.  
  13. Install the sway bar lever with the matchmarks in alignment and tighten the mounting bolt to 38 ft. lbs. (52 Nm).
  14.  
  15. Connect the brake hose bracket to the strut and install the mounting bolt.
  16.  
  17. Connect the ABS sensor to strut bracket.
  18.  
  19. Connect the sway bar to the sway bar link.
  20.  
  21. Install the axle nut and tighten to 137 ft. lbs. (187 Nm).
  22.  
  23. Install the dust cap.
  24.  
  25. Install the tire and wheel assembly.
  26.  
  27. Lower the vehicle.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Check the front end alignment and adjust as necessary.
  32.  

OVERHAUL



See Figures 28 through 51

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Fig. Fig. 28: Exploded view of the front halfshaft assembly with free-tripod joint-SVX shown



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Fig. Fig. 29: Removing the bands from the bands from the joint



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Fig. Fig. 30: Remove the large circlip from the outer race



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Fig. Fig. 31: Orientation of the CV-joint when assembled



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Fig. Fig. 32: Remove the snapring to remove the joint



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Fig. Fig. 33: Inner race and cage-align the cage with the protruded part of the inner race



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Fig. Fig. 34: Install the inner race and ball assembly into the outer race



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Fig. Fig. 35: Make sure the circlip is securely in the outer race and not in the ball groove



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Fig. Fig. 36: Install the CV-boot and band-make sure to pull the band snug



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Fig. Fig. 37: Use a hammer, tap the band end down until it is snug-use care not to rip the boot



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Fig. Fig. 38: Check the CV-boot for wear



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Fig. Fig. 39: Removing the outer band from the CV-boot



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Fig. Fig. 40: Removing the inner band from the CV-boot



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Fig. Fig. 41: Removing the CV-boot from the joint housing



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Fig. Fig. 42: Clean the CV-joint housing prior to removing boot



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Fig. Fig. 43: Removing the CV-joint housing assembly



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Fig. Fig. 44: Removing the CV-joint



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Fig. Fig. 45: Inspecting the CV-joint housing



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Fig. Fig. 46: Removing the CV-joint outer snapring



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Fig. Fig. 47: Checking the CV-joint snapring for wear



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Fig. Fig. 48: CV-joint snapring (typical)



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Fig. Fig. 49: Removing the CV-joint assembly



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Fig. Fig. 50: Removing the CV-joint inner snapring



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Fig. Fig. 51: Installing the CV-joint assembly (typical)

  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.
  10.  


WARNING
Exercise care to avoid damaging the boot on the inner snapring.

  1. Pull back the constant velocity joint boot and pivot the stub axle around the joint far enough to expose a ball.
  2.  
  3. 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.
  4.  
  5. Remove the retaining snapring, and slide the inner race off the shaft.
  6.  
  7. 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.
  8.  
  9. Install the constant velocity joint inner race on the axle shaft, and retain with a snapring.
  10.  
  11. Assemble the joint in the opposite order of disassembly.
  12.  
  13. Slide the double offset joint cage onto the shaft, with the counterbore toward the end of the shaft.
  14.  
  15. Install the inner race on the shaft, and install the retaining snapring.
  16.  
  17. Position the cage over the inner race, and fill the cage pockets with grease.
  18.  
  19. Insert the balls into the cage.
  20.  
  21. Fill the well in the outer race with approximately 1 oz. grease, and slide the outer race onto the axle shaft.
  22.  
  23. 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.
  24.  
  25. Install the retaining circlip in the grove on the outer race.
  26.  

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.

  1. 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.
  2.  
  3. Fill the constant velocity joint boot with 3 oz. grease, and install the boot over the joint.
  4.  
  5. Band the boots on both joints tightly enough that they cannot be turned by hand.
  6.  


WARNING
Use only grease specified for use in constant velocity joints.

 
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