Subaru ff-1/1300/1400/1600/1800/Brat 1970-1984 Repair Guide

Halfshaft

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REMOVAL & INSTALLATION



  1. Disconnect the negative (-) battery cable.
  2.  
  3. Engage the parking brake. Remove the front wheel grease cap and the cotter pin.
  4.  
  5. Loosen the wheel hub nuts and the halfshaft castle nut.
  6.  



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Fig. Fig. 1 Remove the parking brake cable bracket from the transverse link



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Fig. Fig. 2 Using a pin punch, drive out the spring (roll) pin



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Fig. Fig. 3 Close-up of the spring pin. Always use new pins when installing the shafts

  1. Raise and support the front of the vehicle with jackstands.
  2.  
  3. Remove the wheel lug nuts, the wheel/tire assembly and the hub nut.
  4.  
  5. Release the parking brake.
  6.  
  7. Remove the parking brake cable bracket from the transverse link.
  8.  
  9. Using a pin punch, drive out the Double-Offset Joint (DOJ)-to-transaxle shaft, spring (roll) pin; discard the old pin.
  10.  



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Fig. Fig. 4 Using a ball joint puller tool, separate the tie-rod end from the steering knuckle



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Fig. Fig. 5 Using a cold chisel, drive it into the slit on the steering knuckle housing to expand the joint



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Fig. Fig. 6 Lower the transverse link from the steering knuckle



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Fig. Fig. 7 Push out on the housing to remove the halfshaft from the steering knuckle housing

  1. Remove the disc brake caliper-to-steering knuckle bolts and the brake caliper from the steering knuckle; using a wire, suspend it (DO NOT disconnect the brake hose) from the strut tower.
  2.  
  3. Remove the damper strut-to-steering knuckle bolts.
  4.  
  5. At the tie-rod end ball stud, remove the cotter pin and the castle nut.
  6.  
  7. Using a Ball Joint Puller tool, remove the tie-rod end from the steering knuckle.
  8.  
  9. Remove the transverse link ball stud-to-steering knuckle bolt. Using a cold chisel, drive it into the slit on the steering knuckle housing (to expand the joint), then lower the transverse link from the steering knuckle.
  10.  
  11. Using the Puller tool No. 926470000 or equivalent, press the halfshaft from the steering knuckle housing.
  12.  
  13. Clean and inspect the parts for wear and/or damage.
  14.  

To install:

  1. Install the halfshaft into the steering knuckle housing and attach the Installation Spacer tool No. 925130000 or 922430000 or equivalent, onto the outer bearing inner race; be careful not to damage the oil seal lip.
  2.  
  3. Use a new spring pin and reverse the removal procedures.
  4.  
  5. Tighten the transverse link ball joint-to-housing bolts to 22-29 ft. lbs. (29-39 Nm) and the damper strut-to-housing bolts to 22-29 ft. lbs. (29-39 Nm).
  6.  
  7. Tighten the disc cover-to-housing bolts to 4-19 ft. lbs. (5-25 Nm) and the steering knuckle housing-to-halfshaft nut to 145 ft. lbs. (196 Nm)
  8.  

After tightening the halfshaft nut to specifications, retighten it another 30 degrees further.

OVERHAUL



  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.  

To install:

  1. Install the constant velocity joint inner race on the axle shaft, and retain with a snapring.
  2.  
  3. Assemble the joint in the opposite order of disassembly.
  4.  
  5. Slide the double offset joint cage onto the shaft, with the counterbore toward the end of the shaft.
  6.  
  7. Install the inner race on the shaft, and install the retaining snapring.
  8.  
  9. Position the cage over the inner race, and fill the cage pockets with grease.
  10.  
  11. Insert the balls into the cage.
  12.  
  13. Fill the well in the outer race with approximately 1 oz. (28 g) grease, and slide the outer race onto the axle shaft.
  14.  
  15. Install the retaining circlip, and add 1 oz. (28 g) more grease to the interior of the joint. Fill the boot with approximately 1 oz. (28 g) grease, and slide it into position over the double offset joint.
  16.  
  17. Fill the constant velocity joint boot with 3 oz. grease, and install the boot over the joint.
  18.  
  19. Band the boots on both joints tightly enough that they cannot be turned by hand.
  20.  


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

 
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