Subaru Forester 1998-05

CV-Joints

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Overhaul



  1. Remove the halfshaft from the vehicle.
  2.  
  3. Place alignment marks on the shaft and outer race.
  4.  
  5. Remove the SFJ boot band and boot.
  6.  
  7. Remove the circlip from the SFJ outer race.
  8.  
  9. Remove the SFJ outer race from the shaft assembly. Wipe off the grease.
    NOTE
    This is special grease. Do not confuse it with other greases.

  10.  
  11. Place an alignment mark on the free ring and trunion.
  12.  
  13. Remove the free ring from the trunion. Be careful with the free ring position.
  14.  
  15. Place an alignment mark on the trunion and shaft.
  16.  
  17. Remove the snapring and trunion.
  18.  
  19. Remove the SFJ boot.
  20.  
  21. Position the halfshaft in a vise, between wooden blocks.
  22.  
  23. Raise the boot claws, using the proper tools.
  24.  
  25. Cut and remove the boot.
    NOTE
    Always replace the old boot with a new one.

  26.  
  27. Disassembly is complete, the BJ cannot be disassembled.
    NOTE
    Be sure to use the proper grease, NTG2218 (part number 28093AA000) for the BJ side and SSG6003 (part number 28093TA000) for the SFJ side.

  28.  
  29. Place the BJ boot and the small boot band on the BJ side of the shaft.
  30.  
  31. Position the halfshaft in the vise, using wooden blocks.
  32.  
  33. Apply a coat of grease to the BJ joint. 2.12-2.47 ounces.
  34.  
  35. Apply a coat of grease to the entire inner surface of the boot and shaft. 0.71-1.06 ounces.
    NOTE
    The inside of the larger end of the BJ boot and the boot grove must be cleaned so as to be free from grease and other substances.

  36.  
  37. Install the boot projecting portion to the BJ groove.
  38.  
  39. Set the large boot band in place.
  40.  
  41. Install the boot projecting portion to the shaft groove.
  42.  
  43. Tighten the boot bands using tool ST28099AC100, a torque wrench and flex handle. Tighten the large boot band to 116 ft. lbs. Tighten the small boot band to 98 ft. lbs.
  44.  
  45. Place the SFJ boot at the center of the shaft.
  46.  
  47. Align the alignment marks and install the trunion on the shaft.
  48.  
  49. Install the snapring to the shaft. Be sure that the snapring is completely fitted in the shaft groove.
  50.  
  51. Fill 3.53-3.88 ounces of grease into the interior of the SFJ outer race.
  52.  
  53. Apply a coat of grease to the free ring and trunion.
  54.  
  55. Align the alignment marks on the free ring and trunion. Install the free ring. Be careful with the free ring position.
  56.  
  57. Align the alignment marks on the shaft and outer race, and install the outer race.
  58.  
  59. Install the circlip in the groove on the SFJ outer race. Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
  60.  
  61. Apply an even coat of grease, 1.06-1.41 ounces, to the entire inner surface of the boot.
  62.  
  63. Install the SFJ boot taking care not to twist it.
    NOTE
    The inside of the larger end of the SFJ boot and the boot groove should be cleaned so as to be free from grease and other substances. When installing the SFJ boot, position the outer race of the SFJ at the center of its travel.

  64.  
  65. Put a band through the clip and wind twice in alignment with the groove of the boot. Use a new band.
  66.  
  67. Pinch the end of the band with a pliers. Hold the clip and tighten securely.
    NOTE
    When tightening the boot, exercise care so that the air within the boot is appropriate.

  68.  
  69. Tighten the band using tool ST92509100. Tighten the band until it cannot be moved by hand.
  70.  
  71. Tap on the clip with the punch, at the end of the special tool. Tap to the extent that the boot underneath is not damaged.
  72.  
  73. Cut off band with an allowance of about 0.39 inch left from the clip and bend the allowance over the clip.
    NOTE
    Be careful so that the end of the band is close contact with the clip.

  74.  
  75. Fix up the boot on the BJ in the same manner.
    NOTE
    Extend and retract the SFJ to provide equal grease coating.

  76.  

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Place alignment marks on the shaft and outer race.
  4.  
  5. Remove the AARi boot band and boot.
  6.  
  7. Remove the retainer from the AARi outer race.
  8.  
  9. Remove the AARi outer race from the shaft assembly. Wipe off the grease.
    NOTE
    This is special grease. Do not confuse it with other greases.

  10.  
  11. Place an alignment mark on the trunion and shaft.
  12.  
  13. Remove the snapring and trunion.
  14.  
  15. Remove the spider.
  16.  
  17. Remove the AARi boot.
  18.  
  19. Position the halfshaft in a vise, between wooden blocks.
  20.  
  21. Raise the boot claws, using the proper tools.
  22.  
  23. Cut and remove the boot.
    NOTE
    Always replace the old boot with a new one.

  24.  
  25. Hit the AC joint inner race with a hammer to remove the AC joint from the shaft.
    NOTE
    Be sure to use the proper grease, NTBJ (part number 28395SA010) for the AC side and One Luber C (part number 28395SA000) for the AARi side.

  26.  
  27. Place the AC boot and the small boot band on the AC side of the shaft.
  28.  
  29. Position the halfshaft in the vise, using wooden blocks.
  30.  
  31. Apply a coat of grease to the AC joint. 2.82-3.00 ounces.
  32.  
  33. Apply a coat of grease to the entire inner surface of the boot and shaft. 0.71-1.06 ounces.
    NOTE
    The inside of the larger end of the AC boot and the boot grove must be cleaned so as to be free from grease and other substances.

  34.  
  35. Install the boot projecting portion to the AC groove.
  36.  
  37. Set the large boot band in place.
  38.  
  39. Install the boot projecting portion to the shaft groove.
  40.  
  41. Tighten the boot bands using tool ST28099AC000, a torque wrench and flex handle. Caulked portion clearance of the large boot band should be 0.051 inch, or more. Caulked portion clearance of the small boot band should be 0.051 inch, or more.
  42.  
  43. Place the AARi boot and retainer to the shaft and position it at the center of the shaft.
  44.  
  45. Align the alignment marks and install the trunion on the shaft.
  46.  
  47. Fill 3.53-3.88 ounces of grease into the interior of the AARi outer race.
  48.  
  49. Apply a coat of grease to the free ring and trunion.
  50.  
  51. Align the alignment marks on the free ring and trunion. Install the free ring. Be careful with the free ring position.
  52.  
  53. Align the alignment marks on the shaft and outer race, and install the outer race.
  54.  
  55. Apply an even coat of grease, 1.06-1.41 ounces, to the entire inner surface of the boot.
  56.  
  57. Install the AARi boot taking care not to twist it.
    NOTE
    The inside of the larger end of the AARi boot and the boot groove should be cleaned so as to be free from grease and other substances. When installing the AARi boot, position the outer race of the AARi at the center of its travel.

  58.  
  59. Install a new large boot band and small boot band in the specified position.
  60.  
  61. Tighten the band using tool ST280099AC000. Caulked portion clearance of the large boot band should be 0.04 inch, or less. Caulked portion clearance of the small boot band should be 0.04 inch, or less.
    NOTE
    Extend and retract the AARi to provide equal grease coating.

  62.  

  1. Remove the halfshaft from the vehicle.
  2.  
  3. Place alignment marks on the shaft and outer race.
  4.  
  5. Remove the AARi boot band and boot.
  6.  
  7. Remove the retainer from the AARi outer race.
  8.  
  9. Remove the AARi outer race from the shaft assembly. Wipe off the grease.
    NOTE
    This is special grease. Do not confuse it with other greases.

  10.  
  11. Place an alignment mark on the trunion and shaft.
  12.  
  13. Remove the snapring and trunion.
  14.  
  15. Remove the spider.
  16.  
  17. Remove the AARi boot.
    NOTE
    Be sure to use the proper grease, One Louver C (part number 28395SA000).

  18.  
  19. Place the AARi boot and retainer to the shaft and position it at the center of the shaft.
  20.  
  21. Align the alignment marks and install the trunion on the shaft.
  22.  
  23. Fill 3.53-3.88 ounces of grease into the interior of the AARi outer race.
  24.  
  25. Apply a coat of grease to the free ring and trunion.
  26.  
  27. Align the alignment marks on the shaft and outer race. Install the outer race.
  28.  
  29. Apply an even coat of grease, 1.06-1.41 ounces, to the entire inner surface of the boot.
  30.  
  31. Install the AARi boot taking care not to twist it.
    NOTE
    The inside of the larger end of the AARi boot and the boot groove should be cleaned so as to be free from grease and other substances. When installing the AARi boot, position the outer race of the AARi at the center of its travel.

  32.  
  33. Check the position of the retainer.
  34.  
  35. Install a new large boot band and small boot band in the specified position.
  36.  
  37. Tighten the band using tool ST280099AC000. Clearance at the crimped section of the large boot band should be 0.04 inch, or less. Clearance at the crimped section of the small boot band should be 0.04 inch, or less.
    NOTE
    Extend and retract the AARi to provide equal grease coating.

  38.  

 
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