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Front Suspension: Removal & Installation Subaru Outback BP

Suspension Front 23 illustrations ~1488 words

Removal

  1. Disconnect ground cable from battery.
  2. Jack-up vehicle, support it with safety stands, and remove front wheels.
  3. Unlock axle nut. (Scheme 4) CAUTION: Be sure to loose and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings.
  4. Remove axle nut while depressing brake pedal to prevent front drive shaft from turning.
  5. Remove stabilizer link. (Scheme 5)
  6. Remove disc brake caliper from housing, and suspend it from strut using a wire.
  7. Remove disc rotor from hub. (Scheme 6) If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor.
  8. Remove cotter pin and castle nut which secure tie-rod end to housing knuckle arm. (Scheme 7)
  9. Using a puller, remove tie-rod ball joint from knuckle arm. (Scheme 8)
  10. Remove ABS sensor assembly and harness. (Scheme 9)
  11. Remove bolt which secures sensor harness to strut. (Scheme 10)
  12. Remove transverse link ball joint from housing. (Scheme 11) CAUTION: DO NOT pull inner joint when removing axle shaft.
  13. Remove inner joint from transmission spindle.
  14. Remove front axle shaft assembly from hub. (Scheme 12)
  15. After scribing an alignment mark on camber adjusting bolt head, remove bolts which connect housing and strut, and disconnect housing from strut. (Scheme 13)

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

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

Installation

CAUTIONWhen self-locking nut is removed, replace it with new one.
  1. While aligning alignment mark on camber adjusting bolt head, connect housing and strut.
  2. Install front drive shaft.
  3. Install transverse link ball joint to housing.
  4. Install ABS sensor harness on strut.
  5. Install ABS sensor on housing.
  6. Install disc rotor on hub.
  7. Install disc brake caliper on housing.
  8. Connect stabilizer link. CAUTION: DO NOT hammer the bottom of tie-rod end when installing it.
  9. Install tie-rod end.
  10. After tightening castle nut to specification, retighten it further within 60° until a slot in castle nut is aligned with the ball joint hole. (Scheme 7) See «TORQUE SPECIFICATIONS»(ref-167847-S18446705852004102200000). CAUTION: When axle nut is removed, replace it with new one. Always tighten axle nut before installing wheel on vehicle. Be sure to tighten axle nut to specification. DO NOT over tighten it as this may damage wheel bearing.
  11. While depressing brake pedal to prevent front axle shaft from turning, tighten axle nut to specification.
  12. After tightening axle nut, lock it securely. (Scheme 14)
  13. Install wheel and tighten wheel nuts to specification. See «TORQUE SPECIFICATIONS»(ref-167847-S18446705852004102200000).

Scheme 14

Scheme 14
Scheme 14
  1. Disconnect ground cable from battery.
  2. Jack-up vehicle, support it with safety stands, and remove front wheels.
  3. Unlock axle nut. see scheme 20 CAUTION: Be sure to loose and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings.
  4. Remove axle nut while depressing brake pedal to prevent front drive shaft from turning.
  5. Remove stabilizer link. see scheme 21
  6. Remove disc brake caliper from housing, and suspend it from strut using a wire. CAUTION: Be careful not to damage oil seal lip when removing front drive shaft. When replacing front drive shaft, also replace inner oil seal.
  7. Remove front drive shaft assembly from hub. If it hard to remove, use the axle shaft puller and plate.
  8. Remove disc rotor from hub. see scheme 22 If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor.
  9. Remove cotter pin and castle nut which secure tie-rod end to housing knuckle arm. see scheme 23
  10. Using a puller, remove tie-rod ball joint from knuckle arm. see scheme 24
  11. On ABS equipped models, remove ABS sensor assembly and harness in advance. see scheme 25
  12. Remove transverse link ball joint from housing. see scheme 26
  13. After scribing an alignment mark on camber adjusting bolt head, remove bolts which connect housing and strut, and disconnect housing from strut.
  1. Install transverse link ball joint to housing. CAUTION: Use a new self-locking nut.
  2. While aligning alignment mark on camber adjusting bolt head, connect housing and strut.
  3. Install speed sensor and harness on housing (only vehicle equipped with ABS).
  4. Install disc rotor on hub.
  5. Install disc brake caliper on housing.
  6. Install front drive shaft.
  7. Connect stabilizer link.
  8. Install tie-rod end ball joint on housing knuckle arm. see scheme 23 CAUTION: Use a new axle nut. Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. Be sure to tighten axle nut to specification. See «TORQUE SPECIFICATIONS»(ref-167847-S18446705852004102200000). DO NOT overtighten it.
  9. While depressing brake pedal, tighten axle nut and lock it securely. (Scheme 15)
  10. After tightening axle nut, lock it securely. see scheme 28
  11. Install wheel and tighten wheel nuts to specification. See «TORQUE SPECIFICATIONS»(ref-167847-S18446705852004102200000).

Scheme 15

Scheme 15
Scheme 15
  1. Disconnect stabilizer link from transverse link.
  2. Remove bolt securing ball joint of transverse link to housing. (Scheme 16)
  3. Remove nut (DO NOT remove bolt.) securing transverse link to crossmember.
  4. Remove 2 bolt securing bushing bracket of transverse link to vehicle body at rear bushing location. (Scheme 17)
  5. Extract ball joint from housing.
  6. Remove bolt securing transverse link to crossmember and extract transverse link from crossmember. (Scheme 18)

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

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 the transverse link to body. CAUTION: Discard loosened self-locking nut and replace with a new one.
  2. Install bolts used to connect transverse link to crossmember and temporarily tighten with nut.
  3. Insert ball joint into housing. CAUTION: Discard loosened self-locking nut and replace with a new one.
  4. Connect stabilizer link to transverse link, and temporarily tighten bolts. (Scheme 16) NOTE: Move rear bushing back and forth until transverse link-to-rear bushing clearance is established before tightening. (Scheme 19) Check wheel alignment and adjust if necessary.
  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

Scheme 19

Scheme 19
Scheme 19
  1. Remove the wheel.
  2. Pull out the cotter pin from the ball stud, remove the castle nut, and extract the ball stud from transverse link.
  3. Remove the bolt securing the ball joint to the housing. (Scheme 20)
  4. Extract the ball joint from the housing.

Scheme 20

Scheme 20
Scheme 20
  1. Install ball joint onto housing.
  2. Connect ball joint to transverse link.
  3. Re-tighten castle nut further within 60° until a slot in castle nut is aligned with the hole in ball stud end, then insert new cotter pin and bend it around castle nut.
  4. Install front wheel.
  1. Remove wheel.
  2. Remove bolts securing brake hose from strut. (Scheme 21)
  3. Scribe an alignment mark on the camber adjusting bolt which secures strut to housing.
  4. Remove bolt securing ABS sensor harness. see scheme 35 CAUTION: While holding head of adjusting bolt, loosen self-locking nut.
  5. Remove 2 bolts securing housing to strut.
  6. Remove the 3 nuts securing strut mount to body. (Scheme 22)

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22
  1. Install strut mount at upper side of strut to body and tighten with nuts. CAUTION: While holding head of adjusting bolt, tighten self-locking nut. Be sure to use new self-locking nut.
  2. Position aligning mark on camber adjustment bolt with aligning mark on lower side of strut.
  3. Install ABS sensor harness to strut.
  4. Install bolts which secure brake hose to strut. NOTE: Check wheel alignment and adjust if necessary.
  5. Install wheels.
  1. Jack-up the front part of the vehicle and support it with safety stand (rigid racks).
  2. Remove jack-up plate from lower part of crossmember.
  3. Remove bolts which secure stabilizer to crossmember. (Scheme 23)
  4. Remove bolts which secure stabilizer link to front transverse link. (Scheme 24)

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Note. Install bushing (on front crossmember side) while aligning it with pain mark on stabilizer. Ensure that bushing and stabilizer have the same identification colors when installing. (Scheme 25)

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

Scheme 25

Scheme 25
Scheme 25
  1. Disconnect ground cable from battery.
  2. Lift-up vehicle and remove front tires and wheels.
  3. Remove both stabilizer and jack-up plate. (Scheme 26)
  4. Disconnect tie-rod end from housing.
  5. Remove front exhaust pipe.
  6. Remove front transverse link from front crossmember and body. (Scheme 18)
  7. Remove nuts attaching engine mount cushion rubber to crossmember.
  8. Remove steering universal joint.
  9. Disconnect power steering pipe from steering gear box.
  10. Lift engine by approximately.39" (10 mm) by using chain block. CAUTION: When removing crossmember downward, be careful that tie-rod end does not interfere with SFJ boot.
  11. Support crossmember with a jack, remove nuts securing crossmember to body and lower crossmember gradually along with steering gearbox.

Scheme 26

Scheme 26
Scheme 26
CAUTIONAlways tighten 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 wheel alignment and adjust if necessary.
  2. Purge air from power steering system.

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