Front Axle: Installation

Install the front drive shaft. Refer to INSTALLATION , Front Drive Shaft.
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
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)
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 disc brake.
Tightening torque:

120 N.m (12.24 kgf-m, 88.5 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 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
Courtesy of SUBARU OF AMERICA, INC.
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)
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
Courtesy of SUBARU OF AMERICA, INC.

Service limit:

Maximum: 0.05 mm (0.0020 in)
After tightening the axle nut, lock it securely.

Fig 4: Locking Axle Nut
Courtesy of SUBARU OF AMERICA, INC.
Install the wheel.
Tightening torque:

120 N.m (12.24 kgf-m, 88.5 ft-lb)
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
Courtesy of SUBARU OF AMERICA, INC.
Inspect the wheel alignment and adjust if necessary.