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Front Axle: Installation

WARNING: This page is about a different car, the 2012 Subaru Outback and 2012 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the front drive shaft. Refer to INSTALLATION , Front Drive Shaft.
  2. Install the ball joint to the front axle housing.
    CAUTION: Before tightening, make sure the lower side of front axle housing and stepped section of ball joint are in contact.
    Fig 1: Identifying Ball Joint To Front Axle Housing
    G07914089Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    50 N.m (5.1 kgf-m, 36.9 ft-lb) 

  3. Install the front ABS wheel speed sensor.

    Tightening torque: 

    7.5 N.m (0.76 kgf-m, 5.5 ft-lb) 

  4. Install the disc rotor.
  5. Install the disc brake.

    Tightening torque: 

    120 N.m (12.24 kgf-m, 88.5 ft-lb) 

  6. Install the stabilizer link.

    Tightening torque: 

    60 N.m (6.12 kgf-m, 44.3 ft-lb) 

  7. Connect the tie-rod ends.
    1. Connect the tie-rod ends from the front axle housing.
    2. Tighten the castle nuts to the specified torque.
      CAUTION: When connecting the tie-rod, do not hit the cap at bottom of tie-rod end with a hammer.

      Tightening torque: 

      27 N.m (2.75 kgf-m, 19.9 ft-lb) 

    3. Tighten the castle nut within the range of 60° so that the cotter pin hole and cutout portion of the castle nut are aligned.
    4. Insert the cotter pin, and bend the tip of the pin to fix it.
    Fig 2: Inserting Cotter Pin
    G07914090Courtesy of SUBARU OF AMERICA, INC.
  8. While depressing the brake pedal, tighten a new axle nut to the specified torque and lock it securely.
    CAUTION: Do not load the front axle before tightening the axle nut. Doing so may damage the hub bearing.

    Tightening torque: 

    220 N.m (22.43 kgf-m, 162.3 ft-lb) 

  9. Inspect the lean of axis direction using a dial gauge. Replace the bearing if the load range exceeds the limitation.
    Fig 3: Inspecting Lean Of Axis Direction Using Dial Gauge
    G07914091Courtesy of SUBARU OF AMERICA, INC.

    Service limit: 

    Maximum: 0.05 mm (0.0020 in) 

  10. After tightening the axle nut, lock it securely.
    Fig 4: Locking Axle Nut
    G05032598Courtesy of SUBARU OF AMERICA, INC.
  11. Install the wheel.

    Tightening torque: 

    120 N.m (12.24 kgf-m, 88.5 ft-lb) 

  12. Moving the front tire up and down by hand, check there is no play in bearing, and check the wheel rotates smoothly.
    CAUTION: If there is any fault in the bearing, replace hub unit bearing.
    Fig 5: Moving Front Tire Up And Down
    G05032603Courtesy of SUBARU OF AMERICA, INC.
  13. Inspect the wheel alignment and adjust if necessary.
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