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Front Suspension: Removal & Installation Subaru Forester SG

Suspension Front 28 illustrations ~1514 words

Removal

  1. Disconnect the ground cable from battery.
  2. Lift-up the vehicle, and then remove the front tires and wheels.
  3. Remove the sub-frame. See «SUB-FRAME»(ref-169209-S30898541552004120300000).
  4. Remove both the stabilizer and jack-up plate. (Scheme 4)
  5. Disconnect the tie-rod end from housing.
  6. Remove the front exhaust pipe.
  7. Remove the front transverse link from front crossmember and body. (Scheme 5)
  8. Remove the nuts attaching engine mount cushion rubber to crossmember.
  9. Remove the steering universal joint.
  10. Disconnect the power steering pipe from steering gear box.
  11. Lift the engine by approximately.39" (10 mm) by using chain block. CAUTION: When removing the crossmember downward, be careful that tie-rod end does not interfere with SFJ boot.
  12. Support the crossmember with a jack, remove nuts securing crossmember to body and lower the crossmember gradually along with steering gear box.

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Installation

Note. Always tighten the rubber bushing when wheels are in full contact with the ground and vehicle is curb weight. See TORQUE SPECIFICATIONS .

  1. Install in the reverse order of removal. NOTE: Check the wheel alignment and adjust if necessary.
  2. Purge air from the power steering system.
  1. Lift-up the vehicle and remove the front wheels.
  2. Unlock the axle nut. (Scheme 6)
  3. Remove the axle nut using a socket wrench. CAUTION: Remove the axle nut with vehicle weight not applied on axle. Failure to follow this rule may damage the wheel bearings.
  4. Remove the stabilizer link. (Scheme 7)
  5. Remove the disc brake caliper from housing, and suspend it from strut using a wire.
  6. Remove the disc rotor from hub. (Scheme 8) If the disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor.
  7. Remove the cotter pin and castle nut which secure tie-rod end to housing knuckle arm. (Scheme 9)
  8. Using a puller, remove the tie-rod ball joint from knuckle arm. (Scheme 10)
  9. Remove the ABS sensor assembly and harness. (Scheme 11)
  10. Remove the transverse link ball joint from housing. (Scheme 12) CAUTION: Be sure to replace the differential side retainer oil seat at transmission side with a new one when removing front axle shaft. Suspend the front axle shaft to vehicle body using a wire.
  11. Remove the front drive shaft assembly from hub. (Scheme 13) If it is hard to remove, use axle shaft puller and axle shaft puller plate.
  12. After scribing an alignment mark on the camber adjusting bolt head, remove the bolts which connect housing and strut, and disconnect housing from strut. (Scheme 14)

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14
  1. Temporarily tighten the front axle to front strut.
  2. Insert the front drive shaft into front axle.
  3. Temporarily tighten the axle nut.
  4. Install the transverse link ball joint to housing.
  5. While aligning the alignment mark on the camber adjusting bolt head, tighten the housing and strut using a new self-locking nut. CAUTION: When connecting, DO NOT hit the cap at bottom of tie-rod with hammer.
  6. Connect the tie-rod end ball joint to the knuckle arm with a castle nut.
  7. Tighten the castle nut to specification and tighten further within 60° until pin hole is aligned with the slot in nut. See «TORQUE SPECIFICATIONS»(ref-169209-S14868358582004120200000). Bend the cotter pin to lock.
  8. Install the disc rotor on hub.
  9. Install the disc brake caliper on housing.
  10. Connect the stabilizer link.
  11. Using the axle shaft installer and adapter, pull the front drive shaft into place. (Scheme 15) CAUTION: Be sure to tighten the axle nut to specification. DO NOT overtighten it as this may damage wheel bearing.
  12. While depressing the brake pedal, tighten a new axle nut to specification and lock it securely. See «TORQUE SPECIFICATIONS»(ref-169209-S14868358582004120200000).
  13. After tightening axle nut, lock it securely. (Scheme 16)
  14. Install the ABS sensor on housing.
  15. Install the wheel and tighten wheel to specification.

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Removal & Installation

  1. Disconnect ground cable. Raise and support vehicle. Remove wheel. Using chisel, unstake axle nut and remove. Remove stabilizer bar. Remove brake caliper assembly from steering knuckle without disconnecting hydraulic line. Suspend caliper using a wire.
  2. Disconnect ABS speed sensor (if equipped). Remove front drive shaft assembly by using Axle Shaft Puller (926470000) and Plate (927140000). Remove brake rotor.
  3. Disconnect ball joint from knuckle. Remove tie rod cotter pin and nut. Using a puller, disconnect tie rod end from steering knuckle. Scribe reference mark on strut-to-knuckle retaining bolts. Remove steering knuckle-to-strut retaining bolt(s).
  4. Remove steering knuckle from vehicle. Mount knuckle assembly on Stand (927080000). Mount Hub Remover (927060000) on knuckle assembly, and press out hub. Remove inner seal and snap ring from knuckle. Support knuckle and press out inner bearing.
  5. Remove ABS sensor ring from hub (if equipped). Using bearing splitter, remove bearing and seal from hub. Mount knuckle in press and install inner bearings, outer bearings and seals with appropriate adapters. Ensure bearings are properly lubricated. Install snap ring before installing inner seal.
  6. Mount ABS sensor ring to hub (if equipped). Press hub in knuckle assembly. Mount knuckle on vehicle. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-169209-S14868358582004120200000) .

Scheme 17

Scheme 17
Scheme 17
  1. Remove the wheel.
  2. Pull out the cotter pin from ball stud, remove the castle nut, and extract the ball stud from transverse link.
  3. Remove the bolt securing ball joint to housing. (Scheme 18)
  4. Extract the ball joint from housing.

Scheme 18

Scheme 18
Scheme 18
CAUTIONDO NOT apply grease to tapered portion of ball stud.
  1. Install the ball joint onto housing.
  2. Connect the ball joint to transverse link.
  3. Retighten the castle nut further within 60° until slot in castle nut is aligned with the hole in ball stud end, then insert a new cotter pin and bend it around castle nut.
  4. Install the front wheel.
  1. Remove the wheel.
  2. Remove the bolt securing brake hose from strut. (Scheme 19)
  3. Scribe an alignment mark on the camber adjusting bolt which secures strut to housing.
  4. Remove the bolt securing ABS sensor harness. (Scheme 20) NOTE: While holding the head of adjusting bolt, loosen self-locking nut.
  5. Remove the 2 bolts securing housing to strut.
  6. Remove the 3 nuts securing strut mount to body. (Scheme 21)

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21
  1. Install the strut mount at upper side of strut to body, and then tighten with nuts. NOTE: While holding the head of adjusting bolt, tighten self-locking nut.
  2. Position the aligning mark on camber adjustment bolt with aligning mark on lower side of strut. Install the strut to housing with a new self-locking nut.
  3. Install the ABS sensor harness to strut.
  4. Install the bolts which secure brake hose to strut. NOTE: Check the wheel alignment and adjust if necessary.
  5. Install the wheels.
  1. Jack-up the front part of the vehicle and support it with safety stands (rigid racks).
  2. Remove the jack-up plate from lower part of crossmember.
  3. Remove the sub-frame. See «SUB-FRAME»(ref-169209-S30898541552004120300000).
  4. Remove the nuts which secures stabilizer link to front transverse link. (Scheme 22)
  5. Remove the bolt and nut which secure stabilizer to crossmember. (Scheme 23)

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Note. Install the bushing (on front crossmember side) while aligning it with paint mark on stabilizer. Ensure that bushing and stabilizer have the same identification colors when installing. (Scheme 24)

  1. Install in the reverse order of removal.
  2. Always tighten the rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight.

Scheme 24

Scheme 24
Scheme 24
  1. Set the vehicle on the lift.
  2. Lift-up the vehicle and remove the wheel.
  3. Remove the sub-frame. See «SUB-FRAME»(ref-169209-S30898541552004120300000).
  4. Disconnect the stabilizer link from transverse link.
  5. Remove the bolt securing ball joint of transverse link to housing. (Scheme 25)
  6. Remove the nut (DO NOT remove bolt) securing transverse link to crossmember.
  7. Remove the 2 bolts securing bushing bracket of transverse link to the vehicle body at rear bushing location. (Scheme 26)
  8. Extract the ball joint from housing.
  9. Remove the bolt securing transverse link to crossmember, and then extract the transverse link from crossmember. (Scheme 27)

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Note. These bolts should be tightened to such an extent that they can still move back and forth in the oblong shaped hole in the bracket (which holds the bushing).

  1. Temporarily tighten the 2 bolts used to secure rear bushing of transverse link to body.
  2. Install the bolts used to connect transverse link to crossmember and temporarily tighten with a new self-locking nut.
  3. Insert the ball joint into housing.
  4. Connect the stabilizer link to transverse link and temporarily tighten a new self-locking nut. (Scheme 25)
  5. Tighten the following points in the order shown below when wheels are in full contact with the ground and vehicle is curb weight. Transverse link and stabilizer Transverse link and crossmember Transverse link rear bushing and body
  6. Check the wheel alignment and adjust if necessary.
  1. Lift-up the vehicle.
  2. Remove the under cover.
  3. Remove the bolt cover. (Scheme 28)
  4. Remove the clip. (Scheme 29) NOTE: Loosen bolt (1) and leave a few threads caught, then remove the bolts in the order of (2), (3), (4), (5), and (6).
  5. Remove the sub-frame. (Scheme 30)

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Note. Replace the M12 bolt with a new one. (Scheme 31)

Install in the reverse order of removal.

Scheme 31

Scheme 31: Installation
Scheme 31: Installation

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