Double Offset Joint and Axle Boot Installation

[How-To Doc]

Double Offset Joint and Axle Boot Installation

Author: Subaru

NUMBER: 03-28-81

DATE: 11-12-81

APPLICABILITY: ALL MODELS

SUBJECT: DOJ AND AXLE BOOT INSTALLATION REVISED PROCEDURES

If it is necessary to replace a front double offset joint (DOJ) or axle boot, it is not necessary to completely disassemble the axle from the outer bearing housing as described in the Subaru Service Manual.

The following procedures describe the proper method of DOJ or DOJ axle boot replacement.

I. REPLACEMENT

1) Release the parking brake and raise the vehicle using recommended lifting points.
2) Disconnect the oxygen (02) sensor cord (if vehicle is so equipped), Take care to grasp the cord at the boot to prevent damage to the cord.
3) Remove the front exhaust pipe.
.....a) Loosen the nuts which secure the front exhaust pipe to the engine and hold its flanges loosely on the engine as shown in Figure 1.

NOTE: Be sure to support the Exhaust System to prevent bending or kinking.

.....b) Remove the bolts which secure the front exhaust pipe to the rear exhaust pipe.
.....c) Remove the bolts from the exhaust pipe mounting bracket as shown in Figure 2, next page.
.....d) Remove the front exhaust pipe.

4) Separate the transverse link from the cross member by removing the transverse link connecting bolt as shown in Figure 3.
5) Drive out the spring in which secures the DOJ to the axle drive shaft using a 6 mm (0.24) steel drift punch, as shown in Figure 4, and pull out the DOJ by hand.
6) Straighten bent claw of the boot bands on both the large and small end of the DOJ boot. Do this with a screw driver using care not to damage the boot if the boot is not to be replaced. See Figure 5.
7) Slide back the big end of boot from the DOJ outer race. Pry out the circlip from the groove near the DOJ opening as shown in Figure 6.
8) Pull DOJ outer race off the inner race assembly as shown in Figure 7.
9) Remove the C type snap ring which holds the DOJ inner race to the axle shaft assy. with the snap ring pliers as shown in Figure B. Remove the DOJ inner race from the axle shaft.
10) Slide the boot off the axle shaft assembly if it is to be replaced.

IF DOJ IS TO BE REUSED:

11) Clean thoroughly, wash grease away from the axle shaft splines.
12) Disassemble the inner race, clean the balls, cage and inner race itself.Inspect the races and balls for scoring or damage.
13) Remove grease thoroughly from inside the DOJ outer race.

NOTE: Using a solvent and a brush, clean the axle shaft splines, inner race and outer race.

II. REASSEMBLY

14) Put a new small boot band on the axle shaft.
15) Fit the DOJ boot in position on the axle shaft.
16) Install the DOJ inner race with the cage positioned correctly on the axle shaft splines. Secure it by fitting the C type snap ring into the groove of the axle shaft with snap ring pliers.
17) Apply 20 to 30 grams (0.7 to 1.0 oz) of grease (Part no. 623 029 980 - Molylex No. 2) to the cage pockets.
18) Fit the six balls into the cage pockets.
19) Apply another 20 to 30 grams (0.7 to 1.0 oz) of grease (Part no. 623 029 980) thoroughly to the inner surface of the DOJ outer race.
20) Install the outer race onto the inner race with the balls aligned with the tracks on the outer race and install circlip.

NOTE 1: Check that the circlip ends are not positioned in any of the ball tracks of the outer race.

NOTE 2: Check that the circlip is completely fitted into the groove by pulling the axle shaft outward lightly.

21) Apply 20 to 30 grams (0.7 to 1.0 oz) of grease (Part no. 623 029 980) to the DOJ's interior.
22) Apply 20 to 30 grams (0.7 to 1.0 oz) of grease (Part no. 623 029 980) to the boot interior and fit the big end of the boot onto the outer race. Clean the band grooves on the boot if they are stained with grease or other substance.
23) Secure the boot ends in position with the now small and large bands.
24) Install the DOJ onto the transaxle drive shaft, aligning the spring pin holes. Drive in a new spring pin.
25) Connect the transverse link with crossmember and install the transfer link mounting bolt. Torque it to the proper specifications. Torque 3.0 - 4.0 kg-m (22-29 ft-lb)
26) Mount the front exhaust pipe using new gaskets and connect the oxygen (02) sensor cord (if so equipped).
27) Lower the vehicle to the ground.

The Flat Rate Times for the procedures are as follows:


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