Front Crossmember: Removal

CAUTION:

The power steering control module continues to operate after the engine stops and calculate the temperature in the control module. Therefore, before starting service of the power steering system which requires disconnection of the connector, stop the engine and allow approx. 30 minutes until the control module becomes cold.
Before removal or installation, be sure to remove any foreign matter (dust, moisture, oil, etc.) from the power steering control module connector.

Disconnect the ground cable from battery. Ref. to NOTE>NOTE>BATTERY .
NOTE:
- For model with battery sensor, disconnect the ground terminal from battery sensor.
Adjust the tilt position of the steering column to the lowest position and lock the tilt lever.

Fig 1: Adjusting Steering Column Tilt Position
Courtesy of SUBARU OF AMERICA, INC.
Lift up the vehicle, and then remove the front wheels.
Remove the under cover COMPL - front. Ref. to EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL .
Remove the universal joint assembly - steering. Ref. to POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>REMOVAL .
Change the front hood stay position from (A) to (B), and completely open the front hood.
Tightening torque:

20 N.m (2 kgf-m, 14.8 ft-lb)

Fig 2: Changing Front Hood Stay Position
Courtesy of SUBARU OF AMERICA, INC.
Remove the bolts and remove the V-belt cover. (Non-turbo model)

Fig 3: Locating V-Belt Cover Bolt (Non-Turbo Model)
Courtesy of SUBARU OF AMERICA, INC.
Remove the clip (A), lift the front of the collector cover in the direction of arrow, and then remove the collector cover. (Turbo model)

Fig 4: Removing Front Crossmember Collector Cover (Turbo Model)
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the connector and harness clamp from power steering control module.
Support the engine with a lifting device and wire ropes.
1. Support the engine with a lifting device and wire ropes.
2. 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.

Fig 5: Supporting Engine Using Lifting Device And Wire Ropes
Courtesy of SUBARU OF AMERICA, INC.
Remove the nuts which secure the engine mounting.
1. Raise up the lifting device, and lift the engine by approx. 10 mm (0.39 in).
2. Remove the nuts which secure the engine mounting to the front crossmember assembly.
Fig 6: Locating Engine Mounting And Front Crossmember Assembly Nuts
Courtesy of SUBARU OF AMERICA, INC.
Remove the center exhaust pipe.
- Non-turbo model: Ref. to EXHAUST(H4DO)>Center Exhaust Pipe>REMOVAL .
- Turbo model: Ref. to EXHAUST(H4DOTC)>Center Exhaust Pipe>REMOVAL .
Remove the under cover front - transmission. (Non-turbo model)
Remove the front crossmember support. Ref. to FRONT SUSPENSION>Front Crossmember Support Plate>REMOVAL .
Remove the front stabilizer. Ref. to FRONT SUSPENSION>Front Stabilizer>REMOVAL .
Disconnect the tie-rod end.
1. Pull out the cotter pin (a).
2. Remove the castle nut (b).
3. Using a tie-rod ball joint puller, remove the tie-rod end (c).
  Preparation tool:
  
  Tie-rod ball joint puller
Fig 7: Removing Tie-Rod End Using Tie-Rod Ball Joint Puller
Courtesy of SUBARU OF AMERICA, INC.
Remove the support plate - front crossmember (a).

Fig 8: Locating Front Crossmember Support Plate Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the front arm assembly. Ref. to FRONT SUSPENSION>Front Arm>REMOVAL .
Support the front crossmember assembly using a jack, and remove the bolts which hold the crossmember on the body.

Fig 9: Locating Crossmember Bolts
Courtesy of SUBARU OF AMERICA, INC.
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.
Remove the steering gearbox assembly from the front crossmember assembly.