Subaru BRZ 2013 · Service Manual Drive train

Rear drive shaft ASSY

Components Removal / installation

DRIVE SHAFT / PROPELLER SHAFT

REAR DRIVE SHAFT ASSY

EXPLODED VIEW

NOTE:

Be sure to use the recommended product or the substitute product for differential oil. (Refer to

)

REMOVAL

1. Lift up the vehicle, and then remove the rear wheels.

2. Disconnect the high control sensor RR LL. (Refer to

)

3. Remove the rear axle shaft nut.

CAUTION:

Do not loosen the rear axle shaft nut with the rear axle loaded. Doing so may damage the rear axle hub & bearing ASSY.

(1) Lift the crimped section of the rear axle shaft nut.

(2) Using a socket wrench, remove the rear axle shaft nut while depressing the brake pedal.

4. Drain differential gear oil. (Refer to

)

5. Remove the propeller shaft. (Refer to

)

6. Loosen the joint of rear differential carrier ASSY and rear drive shaft ASSY.
Using a tool such as a crowbar, loosen the rear drive shaft ASSY attached to the rear differential carrier ASSY as shown in the figure.

CAUTION:

If a crowbar, etc. contacts the cover, the cover may be damaged. A crowbar, etc. is allowed to contact the differential carrier.

7. Disconnect the installation section of rear differential carrier ASSY.

(1) Support the rear differential carrier ASSY with a transmission jack.

(2) Remove 2 bolts which hold the front side of the rear differential carrier ASSY from the rear suspension member SUB-ASSY.

(3) Remove 3 bolts securing the rear differential carrier ASSY to the rear suspension member SUB-ASSY.

8. Completely pull out the rear drive shaft ASSY while lowering the rear differential carrier ASSY.

CAUTION:

Be careful not to damage the boot.

9. Remove the rear drive shaft ASSY from the rear axle carrier.

NOTE:

If it is hard to be removed, use the SST.

SST 926470000 28099PA110

DISASSEMBLY

NOTE:

·The following procedure is for LH side.
·Perform the same procedures for the RH and LH side.

1. Removal of rear drive shaft inboard joint boot clamp NO. 2

(1) Using a flat tip screwdriver or pliers, loosen the rear drive shaft inboard joint boot clamp NO. 2.

CAUTION:

Be careful not to damage the boot.

2. Removal of rear drive shaft inboard joint boot clamp

NOTE:

For the rear drive shaft inboard joint boot clamp, perform the same procedure as the rear drive shaft inboard joint boot clamp NO. 2.

3. Removal of rear drive shaft outboard joint boot clamp NO. 2

NOTE:

For the rear drive shaft outboard joint boot clamp NO. 2, perform the same procedure as the rear drive shaft inboard joint boot clamp NO. 2.

4. Removal of rear drive shaft outboard joint boot clamp

NOTE:

For the rear drive shaft outboard joint boot clamp, perform the same procedure as the rear drive shaft inboard joint boot clamp NO. 2.

5. Removal of snap ring (LH)

(1) Remove the round snap ring at the neck of EDJ outer race with a flat tip screwdriver.

6. Removal of EDJ outer race (LH)

(1) Remove the EDJ outer race from shaft ASSY.

(2) Wipe off grease and take out the ball.

Captions in illustration

*1	EDJ outer race
*2	Grease
*3	Ball (8 pieces)

The grease is a special grease (exclusively provided for constant velocity joints). Do not mix with other greases.

Disassemble the parts taking care not to lose balls.

(3) In order to remove the cage from inner race, turn the cage by a half pitch to the track groove of inner race and shift the cage.

7. Removal of EDJ inner race (LH)

(1) Using pliers, remove the snap ring fixing the inner race to the shaft.

(2) Remove the EDJ inner race.

8. Removal of EDJ boot (LH)

(1) Remove the EDJ cage from shaft, and then remove the EDJ boot.

Wrap shaft splines with vinyl tape to protect the EDJ boot from scratches.

9. Removal of EBJ boot (LH)

(1) Remove the EBJ boot using the same procedures as for the EDJ boot.

The EBJ is a non-disassembly part, so the drive shaft disassembly stops here.

1. Inspection of rear drive shaft ASSY

(1) Check that the joint portion works smoothly and there is no excessive play by moving the joint portion up/down, to the right/left and in the axial direction.

(2) Check each joint boot for cracks, damage or grease leakage.

Carry the drive shaft ASSY while keeping it horizontally.

·The following procedure is for LH side.
·Perform the same procedures for the RH and LH side.

1. Installation of EBJ boot (LH)

(1) Wrap vinyl tape around the shaft splines.

Wrap shaft splines with vinyl tape to protect the boot from scratches.

(2) Install the EBJ boot to the specified position, and fill it with NKG106 grease or equivalent.

Standard value : 50 to 60g{1.76 to 2.12 oz}

2. Installation of EDJ boot (LH)

(1) Place the EDJ boot at the center of shaft.

(2) Insert the EDJ cage into shaft.

Captions in illustration

*1	EDJ cage
*a	Cutout portion

Insert the cage with the cutout portion facing the shaft end, because the EDJ cage has the specified orientation.

3. Installation of EDJ inner race

(1) Install the EDJ inner race on shaft and fix the snap ring in place with pliers.

Confirm that the snap ring is completely fitted in the shaft groove.

4. Installation of EDJ cage

(1) Install the EDJ cage to inner race fixed onto the shaft.

Captions in illustration

*1	EDJ cage
*2	Inner race

Fit the cage with the protruding section aligned with the track on the inner race, and turn by a half pitch.

(2) Fill the inner side of the EDJ outer race with NKG814 grease or equivalent.

Standard value : 80 to 90 g {2.82 to 3.17 oz}

(3) Apply a thin coat of specified grease to the cage pocket and ball.

(4) Insert the ball into the cage pocket.

(5) Align the outer race track and ball positions, and place the shaft, inner race, cage and ball in the original positions, and then fix the outer race in place.

Captions in illustration

*1	Outer race
*2	Grease
*3	Ball (8 pieces)

(6) Install the snap ring to the groove on the EDJ outer race.

·Assure that the balls, cage and inner race are completely fitted in the outer race of EDJ.
·Use care not to place the matched position of snap ring in the ball groove of outer race.
·Pull the shaft lightly and assure that the snap ring is completely fitted in the groove.

(7) Apply an even coat of NKG814 grease or equivalent over the entire inner surface of boot. Also apply grease to the shaft.

Standard value : 20 to 30 g {0.71 to 1.06 oz}

(8) Install the EDJ boot taking care not to twist it.

·The inside of the large end of EDJ boot and the boot groove shall be cleaned thoroughly so as to be free from grease and other substances.
·When installing the EDJ boot, position the outer race of EDJ at center of the stroke.

5. Installation of rear drive shaft outboard joint boot clamp NO. 2

(1) Apply lubricants to the inner surface of a new rear drive shaft outboard joint boot clamp NO. 2.

(2) Install the rear drive shaft outboard joint boot clamp NO. 2 to the EDJ boot, and then temporarily bend the lever.

Wear protective gloves during operation. Use extra caution to prevent hands from being injured.

·When temporarily bending the lever, make sure no bend is found on the band and lever.
·Do not repeat bending the lever many times to prevent the rear drive shaft outboard joint boot clamp NO. 2 from being cut.

(3) While holding the bent lever by hand, bend the buckle.

(4) Using a plastic hammer, tap the buckle to secure.

·Do not tap the buckle excessively with a plastic hammer.
·Install the lever so that there is no lifting portion.
·Make sure that the gap between 2 buckles becomes parallel.

6. Installation of rear drive shaft outboard joint boot clamp

(1) Install a new rear drive shaft outboard joint boot clamp to the outboard joint boot, and then temporarily bend the lever.

Wear protective gloves during operation. Use extra caution to prevent hands from being injured.

·When temporarily bending the lever, make sure no bend is found on the band and lever.
·Do not repeat bending the lever many times to prevent the rear drive shaft outboard joint boot clamp from being cut.

(2) While holding the bent lever by hand, bend the buckle.

(3) Using a plastic hammer, tap the buckle to secure.

·Do not tap the buckle excessively with a plastic hammer.
·Install the lever so that there is no lifting portion.
·Make sure that the gap between 2 buckles becomes parallel.

7. Installation of rear drive shaft inboard joint boot clamp NO. 2

For the rear drive shaft inboard joint boot clamp NO. 2, perform the same procedure as the rear drive shaft outboard joint boot clamp NO. 2.

8. Installation of rear drive shaft inboard joint boot clamp

For the rear drive shaft inboard joint boot clamp, perform the same procedure as the rear drive shaft outboard joint boot clamp.

1. Replace the rear differential side oil seal

After pulling out the axle shaft ASSY, be sure to replace with a new oil seal.

2. Insert the axle shaft ASSY into the rear hub spline, and pull it into the specified position

·Be careful not to damage the magnetic encoder.
·Do not bring the magnetized tool closer to the magnetic encoder.
·Do not tap the axle shaft using a hammer when installing axle shaft ASSY.

Captions in illustration

*1	Magnetic encoder
*2	Rear axle hub & bearing ASSY

3. Temporarily tighten the rear axle shaft nut

4. Install the rear axle shaft ASSY to the rear differential

5. Install the rear differential ASSY to the rear suspension member SUB ASSY

Be sure to use a new self-locking nut.

Standard value: T=62 N·m {632 kgf·cm} {45.7 ft-lbf} Differential ASSY to rear side of rear differential mount cushion (3 bolts)

Standard value: T=95 N·m {969 kgf·cm} {70.1 ft-lbf} Differential ASSY to front side of rear suspension member SUB ASSY (2 bolts)

6. Install the high control sensor RR LH.

Standard value:

Tightening torque=7.5N·m { 76kgf·cm} {5.5 ft-lbf}

7. While pressing the brake pedal, tighten the new axle nuts to the specified torque

Do not apply load to the rear axle before tightening the rear axle shaft nut. Doing so may damage the rear axle hub & bearing ASSY.

Standard value:

Tightening torque=190N·m { 1937kgf·cm} {140.1 ft-lbf}

8. Crimp and lock the rear axle shaft nut securely

9. Fill with differential gear oil (refer to

)

10. Install the rear wheels.

Standard value:

Tightening torque=120N·m { 1224kgf·cm} {88.5 ft-lbf}

11. Reinitialize the head light leveling computer ASSY (Refer to

)