Subaru 2001 IMPREZA Service Manual
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Subaru 2001 IMPREZA Service Manual

Drive shaft system
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2001 IMPREZA SERVICE MANUAL
CHASSIS SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FRONT SUSPENSION
REAR SUSPENSION
WHEEL AND TIRE SYSTEM
DIFFERENTIALS
TRANSFER CASE
DRIVE SHAFT SYSTEM
ABS
ABS (DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS
BR
PB
PS
G1830GE5

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Summary of Contents for Subaru 2001 IMPREZA

  • Page 1 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.

  • Page 2: Table Of Contents

    DRIVE SHAFT SYSTEM Page General Description ..................2 Propeller Shaft ..................16 Front Axle....................19 Rear Axle ....................24 Front Drive Shaft ..................32 Rear Drive Shaft..................37 General Diagnostic Table................41...

  • Page 3: General Description

    GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 1. General Description A: SPECIFICATIONS 1. PROPELLER SHAFT Propeller shaft type DOJ type UJ type — 584 (22.99) Front propeller shaft Joint-to-joint length: L mm (in) 638 (25.12) 643 (25.32) Rear propeller shaft Joint-to-joint length: L mm (in) 713 (28.07) 708 (27.87)
  • Page 4 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 2. FRONT DRIVE SHAFT ASSEMBLY SHAFT Type of drive shaft assembly Shaft diameter Non-turbo 26 mm (1.02 in) EBJ87+SFJ82 Turbo 28 mm (1.10 in) B4M2218E EBJ87+SFJ82 Measuring point DS-3...
  • Page 5 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 3. REAR DRIVE SHAFT ASSEMBLY φ D No. of identification Size Model protrusion on shaft (mm) (mm) EBJ82/DOJ82 Sedan RH 2 (Two) Sedan Turbo EBJ82/DOJ82 Sedan LH 1 (One) BJ79/DOJ79 Sedan R160RH 2 (Two) Sedan 2.0L NA MT BJ79/DOJ79 Sedan R160LH 1 (One) BJ79/DOJ79 Sedan R152R/L...
  • Page 6 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM EBJ82/DOJ82 Sedan RH BJ79/DOJ79 Sedan R152R/L BJ79/DOJ79 Wagon R160RH EBJ82/DOJ82 Sedan LH BJ79/DOJ79 Wagon R152R/L BJ79/DOJ79 Wagon R160LH BJ79/DOJ79 Sedan R160RH EBJ82/DOJ82 Wagon RH Identification protrusion BJ79/DOJ79 Sedan R160LH EBJ82/DOJ82 Wagon LH DS-5...
  • Page 7 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM B: COMPONENT 1. PROPELLER SHAFT DR0010 Propeller shaft (Turbo model) Rear differential (T-type) Tightening torque: N·m (kgf-m, ft-lb) Propeller shaft (Non-Turbo model) Bush T1: 31 (3.2, 23.1) Rear differential (VA-type) T2: 52 (5.3, 38.3) DS-6...
  • Page 8 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 2. FRONT AXLE B4M2213A Baffle plate (SFJ) Boot (SFJ) (17) Housing Spring pin (10) Boot (EBJ) (18) Oil seal (OUT) Outer race (SFJ) (11) EBJ ASSY (19) Hub bolt Snap ring (12) Tone wheel (With ABS) (20) Trunnion (13)

  • Page 9: Rear Axle

    GENERAL DESCRIPTION DRIVE SHAFT SYSTEM 3. REAR AXLE • AWD Model DR0011 Circlip (12) Non-Turbo: BJ ASSY (22) Turbo: EBJ ASSY Baffle plate (DOJ) (23) Axle nut Outer race (DOJ) (13) Baffle plate (*) Snap ring (14) Oil seal (IN. No. 2) Tightening torque: N·m (kgf-m, ft-lb) Inner race (15)
  • Page 10 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM • FWD Model DR0012 Hub cap Hub unit Tightening torque: N·m (kgf-m, ft-lb) O-ring Hub bolt T1: 6 (0.6, 4.4) Axle nut Tone wheel (With ABS) T2: 186 (19, 137) Washer Spindle DS-9...
  • Page 11 • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.

  • Page 12: Special Tools

    GENERAL DESCRIPTION DRIVE SHAFT SYSTEM D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 922431000 AXLE SHAFT • Used for installing axle shaft into housing. INSTALLER • Used with ADAPTER (927390000). B4M2386 925091000 BAND TIGHTENING • Used for tightening boot band. TOOL (A) Jig for band (B) Ratchet wrench...
  • Page 13 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927420000 HUB REMOVER • Used for removing rear hub. • Used with HUB STAND (927080000). H5M0981 927080000 HUB STAND Used for disassembling and assembling hub bolt in hub. B4M2390 927100000 BEARING PULLER •...
  • Page 14 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927390000 ADAPTER Used as an adapter for AXLE SHAFT INSTALLER (922431000). B4M2393 927400000 HOUSING STAND • Used for disassembling and assembling front housing bearing. • Used with BEARING PULLER (927100000). B4M2394 927410000 OIL SEAL...
  • Page 15 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927120000 HUB INSTALLER Used for installing hub. B4M2399 927440000 BEARING • Used for disassembling and assembling rear REMOVER housing bearing. • Used with HOUSING STAND (927430000). H5M0983 927460000 OIL SEAL •...
  • Page 16 GENERAL DESCRIPTION DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA090 OIL SEAL PROTEC- • Used for installing rear drive shaft into rear dif- ferential. • For potecting oil seal. B4M2401 28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear dif- REMOVER ferential.

  • Page 17: Propeller Shaft

    PROPELLER SHAFT DRIVE SHAFT SYSTEM 2. Propeller Shaft 8) Remove the four bolts which hold propeller shaft to rear differential. A: REMOVAL NOTE: • Put matching mark on affected parts before re- NOTE: moval. • Before removing propeller shaft, wrap metal •...
  • Page 18 PROPELLER SHAFT DRIVE SHAFT SYSTEM 11) Install the extension cap to transmission. 3) Install differential mount front cover. NOTE: Tightening torque: If extension cap is not available, place vinyl bag 88 N·m (9.0 kgf-m, 65 ft-lb) over opening and fasten with string to prevent gear oil or ATF from leaking.
  • Page 19 PROPELLER SHAFT DRIVE SHAFT SYSTEM 3. RUNOUT OF PROPELLER SHAFT 1) Remove center exhaust pipes. 2) Remove rear exhaust pipe and muffler. 3) Remove heat shield cover. 4) Turn rear wheels by hand to check for “runout” of propeller shaft. NOTE: Measure runout with a dial gauge at the center of front and rear propeller shaft tubes.

  • Page 20: Front Axle

    FRONT AXLE DRIVE SHAFT SYSTEM 3. Front Axle CAUTION: • Be careful not to damage oil seal lip when re- A: REMOVAL moving front drive shaft. 1) Disconnect ground cable from battery. • When replacing front drive shaft, also replace 2) Jack-up vehicle, support it with safety stands, inner oil seal.
  • Page 21 FRONT AXLE DRIVE SHAFT SYSTEM 10) Using a puller, remove tie-rod ball joint from B: INSTALLATION knuckle arm. 1) Install transverse link ball joint to housing. Tightening torque: 49 N·m (5.0 kgf-m, 36 ft-lb) 2) While aligning alignment mark on camber adjust- ing bolt head, connect housing and strut.
  • Page 22 FRONT AXLE DRIVE SHAFT SYSTEM C: DISASSEMBLY CAUTION: • Use a new axle nut. 1) Using ST1, support housing and hub securely. • Always tighten axle nut before installing 2) Attach ST2 to housing and drive hub out. wheel on vehicle. If wheel is installed and ST1 927060000 HUB REMOVER comes in contact with ground when axle nut is...
  • Page 23 FRONT AXLE DRIVE SHAFT SYSTEM 4) Using a standard screwdriver, remove outer and D: ASSEMBLY inner oil seals. 1) Attach hub to ST securely. ST 927080000 HUB STAND CAUTION: Do not use old oil seals. 5) Using flat bladed screwdriver, remove snap ring. CAUTION: Be careful not to damage housing at removal.
  • Page 24 FRONT AXLE DRIVE SHAFT SYSTEM 5) Using pliers, install snap ring in its groove. 11) Attach hub to ST1 securely. 12) Clean dust or foreign particles from the pol- CAUTION: ished surface of hub. Make sure to install it firmly to groove. 13) Using ST2, press bearing into hub by driving in- ner race.

  • Page 25: Rear Axle

    REAR AXLE DRIVE SHAFT SYSTEM 4. Rear Axle 9) Disconnect rear stabilizer from rear lateral link. 10) Remove bolts which secure trailing link assem- A: REMOVAL bly to rear housing. CAUTION: 1. DISC BRAKE Discard old self-locking nut. Relpace with a 1) Disconnect ground cable from battery.
  • Page 26 REAR AXLE DRIVE SHAFT SYSTEM 13) Remove rear ABS sensor from back plate 7) If it is difficult to remove brake drum, remove ad- (only vehicle equipped with ABS). justing hole cover from back plate, and then turn adjusting screw using a slot-type screwdriver until brake shoe separates from the drum.
  • Page 27 REAR AXLE DRIVE SHAFT SYSTEM 10) Disconnect rear stabilizer from rear lateral link. 14) Remove rear ABS sensor from back plate (only 11) Remove bolts which secure trailing link assem- vehicle equipped with ABS). bly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one.
  • Page 28 REAR AXLE DRIVE SHAFT SYSTEM B: INSTALLATION 7) Install disc rotor on rear housing assembly. 8) Install disc brake caliper on back plate. 1. DISC BRAKE Tightening torque: 1) Connect rear housing assembly and strut as- 52 N·m (5.3 kgf-m, 38.3 ft-lb) sembly.
  • Page 29 REAR AXLE DRIVE SHAFT SYSTEM 2. DRUM BRAKE 8) Connect rear ABS sensor to back plate (only ve- hicle equipped with ABS). 1) Connect rear housing assembly and strut as- sembly. CAUTION: Use a new self-locking nut. Tightening torque: 196 N·m (20 kgf-m, 145 ft-lb) 2) Fit BJ (bell joint) to rear housing splines.
  • Page 30 REAR AXLE DRIVE SHAFT SYSTEM C: DISASSEMBLY 7) Using ST, press hub bolt out. ST 927080000 HUB STAND 1) Using ST1 and ST2, remove hub from rear hous- ing. CAUTION: ST 927080000 HUB STAND Be careful not to hammer hub bolts. This may ST 927420000 HUB REMOVER deform hub.
  • Page 31 REAR AXLE DRIVE SHAFT SYSTEM D: ASSEMBLY 3) Clean housing interior completely. Using ST1 and ST2, press bearing into housing. 1) Using ST, press new hub bolt into place. ST1 927430000 HOUSING STAND CAUTION: ST2 927440000 BEARING REMOVER • Ensure hub bolt closely contacts hub. CAUTION: •...
  • Page 32 REAR AXLE DRIVE SHAFT SYSTEM 7) Using ST2, press inner oil seal into housing until E: INSPECTION it touches bottom. Check the removed parts for wear and damage. If ST1 927430000 HOUSING STAND defective, replace with a new one. ST2 927460000 OIL SEAL INSTALLER CAUTION: •...

  • Page 33: Front Drive Shaft

    FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 5. Front Drive Shaft B: INSTALLATION 1) Insert BJ into hub splines. A: REMOVAL CAUTION: 1) Disconnect ground cable from battery. Be careful not to damage inner oil seal lip and 2) Jack-up vehicle, support it with safety stands tone wheel.
  • Page 34 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM • Be sure to tighten axle nut to specified 6) Place alignment mark on free ring and trunnion. torque. Do not overtighten it as this may dam- age wheel bearing. 8) After tightening axle nut, lock it securely. C: DISASSEMBLY 1) Place alignment marks on shaft and outer race.
  • Page 35 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 1) Place BJ boot and small boot band on BJ side of CAUTION: shaft. Do not place drive shaft directly in the vise; use wooden block. CAUTION: 12) Raise boot band claws by means of screwdriv- Be sure to wrap shaft splines with vinyl tape to er and hammer.
  • Page 36 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 8) Tighten boot bands using ST, torque wrench and CAUTION: socket flex handle. Be careful with the free ring position. ST 28099AC000 BOOT BAND PLIER B4M0693C (A) Large boot band (B) Boot (C) Torque wrench (D) Socket flex handle (E) BJ Tightening torque:...
  • Page 37 FRONT DRIVE SHAFT DRIVE SHAFT SYSTEM 20) Pinch the end of band with pliers. Hold the clip E: INSPECTION and tighten securely. Check the removed parts for damage, wear, corro- sion etc. If faulty, repair or replace. NOTE: 1) DOJ (Double Offset Joint) When tightening boot, exercise care so that the air Check seizure, corrosion, damage, wear and ex- within the boot is appropriate.

  • Page 38: Rear Drive Shaft

    REAR DRIVE SHAFT DRIVE SHAFT SYSTEM 6. Rear Drive Shaft B: INSTALLATION 1) Insert BJ into rear hub splines. A: REMOVAL CAUTION: 1) Disconnect ground cable from battery. Be careful not to damage tone wheel. 2) Lift-up vehicle, and remove rear wheel cap and 2) Using ST1 and ST2, pull drive shaft into place.
  • Page 39 REAR DRIVE SHAFT DRIVE SHAFT SYSTEM C: DISASSEMBLY 8) To remove the cage from the inner race, turn the cage by a half pitch to the track groove of the inner 1) Straighten bent claw of larger end of DOJ boot. race and shift the cage.
  • Page 40 REAR DRIVE SHAFT DRIVE SHAFT SYSTEM D: ASSEMBLY CAUTION: Use specified grease. BJ side: Molylex No. 2 (Part No. 723223010) DOJ side: VU-3A702 (Yellow) (Part No. 23223GA050) 1) Install BJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 oz) of specified grease. B4M0228E 2) Place DOJ boot at the center of shaft.
  • Page 41 REAR DRIVE SHAFT DRIVE SHAFT SYSTEM 10) Install circlip in the groove on DOJ outer race. 16) Tap on the clip with the punch provided at the end of ST. NOTE: ST 925091000 BAND TIGHTENING TOOL • Assure that the balls, cage and inner race are completely fitted in the outer race of DOJ.

  • Page 42: General Diagnostic Table

    GENERAL DIAGNOSTIC TABLE DRIVE SHAFT SYSTEM 7. General Diagnostic Table A:INSPECTION NOTE: Vibration while cruising may be caused by an un- balanced tire, improper tire inflation pressure, im- proper wheel alignment, etc. Symptom Possible cause Remedy 1. Vibration of propeller shaft (1) Worn or damaged universal joint.
  • Page 43 GENERAL DIAGNOSTIC TABLE DRIVE SHAFT SYSTEM DS-42...

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