Front Suspension (Except Wrx): Removal & Installation Subaru XV GP

REMOVAL

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1. Disconnect the ground cable from battery.
2. Adjust the tilt position of the steering column to the lowest position and lock the tilt lever.
3. Lift up the vehicle, and then remove the front wheels.
4. Remove the bolts and clips, and remove the under cover - front.
5. Remove the universal joint assembly - steering. Place alignment marks on the universal joint assembly - steering. NOTE: Place alignment marks on the following positions. Between the column assembly - steering and the universal joint assembly - steering Between the steering gearbox assembly and the universal joint assembly - steering Remove the bolt, and remove the universal joint assembly - steering.
6. Prevent the steering wheel from turning using the seat belt.
7. Change the front hood stay position from (A) to (B), and completely open the front hood.
8. Remove the V-belt covers.
9. Disconnect the connector and harness clamp from power steering control module.
10. Support the engine with a lifting device and wire ropes. Support the engine with a lifting device and wire ropes. While lifting up the vehicle, also raise up the lifting device. CAUTION: When lifting up the vehicle, raise up wire ropes at the same time.
11. Remove the nuts which secure the engine mounting. Raise up the lifting device, and lift the engine by approx. 10 mm (0.39 in). Remove the nuts which secure the engine mounting to the front crossmember assembly.
12. Remove the bolts, and remove the front crossmember support.
13. Remove the front exhaust pipe. < Refer to «REMOVAL»(ref-560376-S32386970822013061300000) , Front Exhaust Pipe. >
14. Remove the front stabilizer. Remove the left and right stabilizer links. Remove the clamp - stabilizer bushing on the left and right sides.
15. Disconnect the tie-rod end. Pull out the cotter pin (a). Remove the castle nut (b). Using a tie-rod ball joint puller, remove the tie-rod end (c). Preparation tool: Tie-rod ball joint puller
16. Remove the support plate - front crossmember (a).
17. Remove the front arm assembly. Remove the bolt, and then detach the front support. Remove the bolts and nuts, and then remove the front arm rear plate. Remove the nut and disconnect the stabilizer link assembly. Pull out the cotter pin (a), remove the castle nut (b), and remove the ball joint from front arm assembly. Remove the nuts, pull out the flange bolt, and remove the front arm assembly.
18. Support the front crossmember assembly using a jack, and remove the bolts which hold the crossmember on the body.
19. Slowly lower the front crossmember assembly with the steering gearbox assembly as a single unit. CAUTION: When removing the crossmember, make sure that the tie-rod end does not interfere with the drive shaft boot.
20. Remove the steering gearbox assembly from the front crossmember assembly.

Scheme 28

1. Check the crossmember for damage or cracks, and correct or replace if defective.
2. Install the universal joint assembly - steering. < Refer to «INSTALLATION»(ref-560370-S24061683612013061300000) , Universal Joint. >
3. Install each part in the reverse order of removal. CAUTION: Use a new bolt and self-locking nut. For parts which are not reusable, < Refer to «COMPONENT»(ref-560366-S24014389272013061300000) , General Description. > Always tighten the bushing in the state where the vehicle is at curb weight and the wheels are in full contact with the ground. Install the clamp - stabilizer bushing with the arrow mark facing the front of the vehicle. Tightening torque: Engine mount - front crossmember assembly: 45 N.m (4.59 kgf-m, 33.2 ft-lb) Universal joint assembly - steering: 24 N.m (2.45 kgf-m, 17.7 ft-lb) V-belt cover: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb) Under cover - front: 17.5 N.m (1.78 kgf-m, 12.9 ft-lb) Front suspension parts: < Refer to «FRONT SUSPENSION»(ref-560366-S38008096662013061300000) , COMPONENT, General Description. > When tightening the castle nut, tighten the castle nut to the specified torque first, then tighten it further but within 60° until the hole in the ball stud is aligned with a slot in castle nut.
4. Install the front wheels. Tightening torque: 120 N.m (12.24 kgf-m, 88.5 ft-lb)
5. Inspect the wheel alignment and adjust if necessary. Inspection: < Refer to «INSPECTION»(ref-560366-S23660359242013061300000) , Wheel Alignment. > Adjustment: < Refer to «ADJUSTMENT»(ref-560366-S32708602592013061300000) , Wheel Alignment. > CAUTION: When the wheel alignment has been adjusted, perform "VDC sensor midpoint setting mode" of the VDC.
6. Perform reinitialization of the auto headlight beam leveler system. (Model with auto headlight beam leveler) < Refer to «PROCEDURE»(ref-560378-S16380510932013061300000) , Auto Headlight Beam Leveler System. >

Scheme 29

1. Lift up the vehicle.
2. Remove the bolts and clips, and remove the under cover - front.
3. Remove the bolt, and remove the front crossmember support.

INSTALLATION

Install each part in the reverse order of removal.

Tightening torque

Front crossmember support - front crossmember assembly: 60 N.m (6.12 kgf-m, 44.3 ft-lb)

Under cover - front: 17.5 N.m (1.78 kgf-m, 12.9 ft-lb)

Scheme 30

1. Lift up the vehicle, and then remove the left and right front wheels.
2. Remove the bolts and clips, and remove the under cover - front.
3. Remove the bolt, and remove the front crossmember support.
4. Remove the front stabilizer. Remove the left and right stabilizer links. Remove the clamp - stabilizer bushing on the left and right sides.

1. Before installation, inspect the following items and replace any faulty part with a new one. Check the bushing - stabilizer for abnormal cracks, fatigue or damage. Check the stabilizer link assembly for damage.
2. Install each part in the reverse order of removal. CAUTION: Install the clamp - stabilizer bushing with the arrow mark facing the front of the vehicle. Tightening torque: Clamp - stabilizer bushing: 25 N.m (2.55 kgf-m, 18.4 ft-lb) Stabilizer link assembly: 38 N.m (3.87 kgf-m, 28.0 ft-lb) Support plate - front crossmember: 60 N.m (6.12 kgf-m, 44.3 ft-lb) Under cover - front: 17.5 N.m (1.78 kgf-m, 12.9 ft-lb)
3. Install the front wheels. Tightening torque: 120 N.m (12.24 kgf-m, 88.5 ft-lb)

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1. Lift up the vehicle, and then remove the front wheels.
2. Remove the clamp - stabilizer bushing on the left and right sides.
3. Remove the ball joint assembly. Pull out the cotter pin (a), and remove the castle nut (b). Lower the front arm assembly, and remove the ball stud. Remove the bolt from the housing assembly - front axle. Extract the ball joint assembly from the housing assembly - front axle.

Scheme 33

1. Install the ball joint assembly to the housing assembly - front axle. CAUTION: Do not apply grease to the tapered portion of ball stud. Before tightening, make sure the bottom surface of the housing assembly - front axle and the stepped section of ball joint are in contact. Tightening torque: 50 N.m (5.10 kgf-m, 36.9 ft-lb)
2. Install the ball joint assembly to the front arm assembly. Connect the ball joint assembly to the front arm assembly. Tightening torque: 39 N.m (3.98 kgf-m, 28.8 ft-lb) Retighten the castle nut further up to 60° until the hole in the ball stud is aligned with a slot in castle nut. Insert a new cotter pin and bend it around the castle nut.
3. Install the clamp - stabilizer bushing. CAUTION: Install the clamp - stabilizer bushing with the arrow mark facing the front of the vehicle. Tightening torque: 25 N.m (2.55 kgf-m, 18.4 ft-lb)
4. Install the front wheels. Tightening torque: 120 N.m (12.24 kgf-m, 88.5 ft-lb)

Scheme 34

1. Check that there is no play by moving the upper and lower portions of front tire in an axial direction with the brake pedal depressed. Play exists. --> Replace the ball joint assembly. < Refer to «REMOVAL»(ref-560366-S41344542562013061300000) , Front Ball Joint. >
2. Check that there is no play by moving the upper and lower portions of front tire in an axial direction with the brake pedal released. Play exists. --> Check the hub unit COMPL - front axle. < Refer to «INSPECTION»(ref-560368-S25327405392013061300000) , Front Hub Unit Bearing. >
3. Replace the ball joint assembly if the dust cover is damaged when visually inspecting the dust cover.

1. Lift up the vehicle, and then remove the front wheels.
2. Remove the front arm assembly. Remove the bolt, and then detach the front support. Remove the bolts and nuts, and then remove the front arm rear plate. Remove the nut and disconnect the stabilizer link assembly. Pull out the cotter pin (a), remove the castle nut (b), and remove the ball joint assembly from front arm assembly. Remove the nuts, pull out the flange bolt, and remove the front arm assembly.

Scheme 35

1. Before installation, inspect the following items and replace any faulty part with a new one. Check the front arm assembly for damage or cracks, and replace if defective. Visually check the bushing for abnormal cracks, fatigue or damage. Visually check the dust cover on the ball joint assembly for damage.
2. Using new self-locking nuts and flange bolts, temporarily tighten the front arm assembly to the front crossmember assembly.
3. Install the ball joint assembly to the housing assembly - front axle. CAUTION: Before tightening, make sure the bottom surface of the housing assembly - front axle and the stepped section of ball joint are in contact. Tightening torque: 50 N.m (5.10 kgf-m, 36.9 ft-lb)
4. Install the stabilizer link assembly. Tightening torque: Except for XV model: 38 N.m (3.87 kgf-m, 28.0 ft-lb) XV model: 60 N.m (6.12 kgf-m, 44.3 ft-lb)
5. Install the front wheels. Tightening torque: 120 N.m (12.24 kgf-m, 88.5 ft-lb)
6. Unload the vehicle from the lift, and tighten the bolt which secures the front arm assembly to the front crossmember assembly while the wheels are in full contact with the ground and the vehicle is at curb weight. Tightening torque: Busing front - front arm: 95 N.m (9.7 kgf-m, 70.1 ft-lb) Busing rear - front arm: 110 N.m (11.22 kgf-m, 81.1 ft-lb)
7. Inspect the wheel alignment and adjust if necessary. Inspection: < Refer to «INSPECTION»(ref-560366-S23660359242013061300000) , Wheel Alignment. > Adjustment: < Refer to «ADJUSTMENT»(ref-560366-S32708602592013061300000) , Wheel Alignment. > CAUTION: When the wheel alignment has been adjusted, perform " «VDC SENSOR MIDPOINT SETTING MODE»(ref-560389-S40582429032013061300000) " of the VDC.
8. Perform reinitialization of the auto headlight beam leveler system. (Model with auto headlight beam leveler) < Refer to «PROCEDURE»(ref-560378-S16380510932013061300000) , Auto Headlight Beam Leveler System. >

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1. Put an alignment mark on the front arm assembly based on the split portion of the bushing intermediate plate of the busing front - front arm. CAUTION: Always put an alignment mark for aligning the position on bushing installation.
2. Using the ST and a press, remove the busing front - front arm. PREPARATION TOOL: ST: INSTALLER & REMOVER SET (927680000)

Scheme 38

1. Put an alignment mark on the front arm assembly based on the center of recess portion of the busing rear - front arm.
2. Using the ST and a press, remove the busing rear - front arm. PREPARATION TOOL: ST1: REMOVER (20299AG000) ST2: BASE (20299AG010)

1. Install the strut mount - front at the upper side of the strut to the body, and tighten it with new self-locking nuts. Tightening torque: 20 N.m (2.04 kgf-m, 14.8 ft-lb)
2. Align alignment marks on the camber adjusting bolt and strut. Using new self-locking nuts, install the strut to the housing assembly - front axle. NOTE: While holding the head of adjusting bolt, tighten the nut. Tightening torque: 155 N.m (15.81 kgf-m, 114.3 ft-lb)
3. Secure the ABS wheel speed sensor harness bracket to the strut. CAUTION: During the installation, make sure that the marking of ABS wheel speed sensor harness does not twist.
4. Install the brake hose bracket. Tightening torque: 33 N.m (3.36 kgf-m, 24.3 ft-lb)
5. Install the front wheels. Tightening torque: 120 N.m (12.24 kgf-m, 88.5 ft-lb)
6. Inspect the wheel alignment and adjust if necessary. Inspection: < Refer to «INSPECTION»(ref-560366-S23660359242013061300000) , Wheel Alignment. > Adjustment: < Refer to «ADJUSTMENT»(ref-560366-S32708602592013061300000) , Wheel Alignment. > CAUTION: When the wheel alignment has been adjusted, perform " «VDC SENSOR MIDPOINT SETTING MODE»(ref-560389-S40582429032013061300000) " of the VDC.
7. Perform reinitialization of the auto headlight beam leveler system. (Model with auto headlight beam leveler) < Refer to «PROCEDURE»(ref-560378-S16380510932013061300000) , Auto Headlight Beam Leveler System. >

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1. Using a coil spring compressor, compress the coil spring - front.
2. Using the ST, remove the self-locking nut. PREPARATION TOOL: ST: STRUT MOUNT SOCKET (20399AG000)
3. Remove the strut mount - front, spacer - front strut and spring seat - front strut UPR from the strut.
4. Gradually decrease the compression pressure of compressor, and remove the coil spring - front.
5. Remove the dust cover - inner and the helper - front strut.

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1. Before assembly, check each part. < Refer to «INSPECTION»(ref-560366-S31781446472013061300000) , Front Strut. >
2. Using a coil spring compressor, compress the coil spring - front. NOTE: Make sure that the vertical installation direction of the coil spring - front is as shown in the figure.
3. Set the coil spring - front correctly so that its end face (a) contacts the vertical surface (b) of the spring seat - front strut UPR as shown in the figure.
4. Install the dust cover - inner and the helper - front strut to the piston rod.
5. Pull the piston rod fully upward, and install the spring seat. NOTE: Position the spring seat - front strut UPR as shown in the figure.
6. Install the spacer - front strut and the strut mount - front to the piston rod, and temporarily tighten a new self-locking nut.
7. Using a hexagon wrench to prevent strut rod from turning, tighten the new self-locking nut with ST. PREPARATION TOOL: ST: STRUT MOUNT SOCKET (20399AG000) Tightening torque: 55 N.m (5.61 kgf-m, 40.6 ft-lb)
8. Loosen the coil spring compressor carefully.