Front Axle: Installation

Install the front drive shaft assembly.
CAUTION:
- Do not hammer the drive shaft assembly when installing.
- Use new nut - axle.
1. Insert the drive shaft assembly into the hub spline, and pull it into the specified position.
2. Install the housing assembly - front axle to the strut assembly.
  CAUTION: Align alignment marks on the adjusting bolt and strut assembly before installation.
  
  Tightening torque:
  
  155 N.m (15.81 kgf-m, 114.3 ft-lb)
3. Temporarily tighten the nut - axle.
Install the ball joint into 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.
Tightening torque:

50 N.m (5.10 kgf-m, 36.9 ft-lb)

Fig 1: Locating Ball Joint Bolt
Courtesy of SUBARU OF AMERICA, INC.
Install the front ABS wheel speed sensor.
Tightening torque:

7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
Install the disc rotor.
Install the caliper body assembly and the brake hose bracket.
Tightening torque:

Brake hose bracket: 33 N.m (3.36 kgf-m, 24.3 ft-lb)

Mounting bolt: 80 N.m (8.16 kgf-m, 59.0 ft-lb)
Install the stabilizer link.
Tightening torque:

60 N.m (6.12 kgf-m, 44.3 ft-lb)
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.
  
  Fig 2: Identifying Cotter Pin, Castle Nut And Tie-Rod End
  Courtesy of SUBARU OF AMERICA, INC.
4. Insert the cotter pin (a), and bend the tip of the pin to fix it.
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)
After tightening the nut - axle, lock it securely.

Fig 3: Tightening Axle Nut
Courtesy of SUBARU OF AMERICA, INC.
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 looseness by moving the upper and lower portions of front tire in an axial direction with the brake pedal released.
  - Looseness exists → Check the hub unit COMPL - front axle. Ref. to DRIVE SHAFT SYSTEM>Front Hub Unit Bearing>INSPECTION .
  Fig 4: Moving Upper And Lower Portions Of Front Tire
  Courtesy of SUBARU OF AMERICA, INC.
3. Check that there is no looseness by moving the upper and lower portions of front tire in an axial direction with the brake pedal depressed.
  - Looseness exists → Replace the ball joint. Ref. to FRONT SUSPENSION>Front Ball Joint>REMOVAL .
Inspect the wheel alignment and adjust if necessary.
- Inspection: Ref. to FRONT SUSPENSION>Wheel Alignment>INSPECTION .
- Adjustment: Ref. to FRONT SUSPENSION>Wheel Alignment>ADJUSTMENT .
CAUTION: When the wheel alignment has been adjusted, perform "VDC sensor midpoint setting mode".
Perform reinitialization of the auto headlight beam leveler system. (Model with auto headlight beam leveler) Ref. to LIGHTING SYSTEM>Auto Headlight Beam Leveler System>PROCEDURE .