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Front Axle: Installation

WARNING: This page is about a different car, the 2014 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the front axle shaft assembly.
    CAUTION:
    • Do not tap the axle shaft using a hammer when installing axle shaft assembly.
    • Use new nut - axle.
    1. Insert the axle shaft assembly into the hub spline, and pull in the axle shaft assembly into specified position.
    2. Temporarily tighten the nut - axle.
  2. 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.
    • Be careful not to damage the boot of the joint.
    Fig 1: Locating Bolts Of Ball Joint To Housing Assembly - Front Axle
    G09483305Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    50 N.m (5.10 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 caliper body assembly.

    Tightening torque: 

    80 N.m (8.16 kgf-m, 59.0 ft-lb) 

  6. Install the stabilizer link assembly.

    Tightening torque: 

    60 N.m (6.12 kgf-m, 44.3 ft-lb) 

  7. Connect the tie-rod ends.
    1. Connect the tie-rod end (c) to the housing assembly - front axle.
    2. Tighten the castle nuts (b) 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 (b) within the range of 60° so that the cotter pin (a) hole and cutout portion of the castle nut (b) are aligned.
    4. Insert the cotter pin (a), and bend the tip of the pin to fix it.
      Fig 2: Removing Castle Nut And Cotter Pin
      G09482929Courtesy of SUBARU OF AMERICA, INC.
  8. While depressing the brake pedal, tighten a new nut - axle to the specified torque and lock it securely.
    CAUTION: Do not load the front axle before tightening the nut - axle. Doing so may damage the hub unit COMPL.

    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 hub unit COMPL - front axle if the play exceeds the limit.
    Fig 3: Checking Lean Of Axis Direction Using Dial Gauge
    G09483307Courtesy of SUBARU OF AMERICA, INC.

    Service limit: 

    Maximum: 0.05 mm (0.0020 in) 

  10. After tightening the nut - axle, lock it securely.
    Fig 4: Locking Axle Nut
    G05032598Courtesy of SUBARU OF AMERICA, INC.
  11. Install the front wheels, and perform the following inspections.

    Tightening torque: 

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

    1. Check the wheels for smooth rotation.
    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.
      Fig 5: Checking Wheels For Smooth Rotation
      G08318673Courtesy of SUBARU OF AMERICA, INC.
      • Play exists  → Check the hub unit COMPL - front axle. < Ref. to INSPECTION , Front Hub Unit Bearing. >
    3. 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. < Ref. to REMOVAL , Front Ball Joint. >
  12. Inspect the wheel alignment and adjust if necessary.
  13. Perform reinitialization of the auto headlight beam leveler system. (Model with auto headlight beam leveler) < Ref. to PROCEDURE , Auto Headlight Beam Leveler System. >
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