Chassis/Hardware Kit Installation

Parts Needed





1) Install the front engine mount insert (4 cylinder models only)





a) Use a transmission jack to lift the engine assembly approximately 10mm. This will create a gap in the front engine mount where the insert will be placed.





b) Insert the engine mount insert into the gap above the front engine mount horizontal bolt. The two opposing tabs on the insert will point toward the front and rear of the car, not up and down.

c) Lower the engine down into the normal at rest position.

d) Install the front exhaust pipe.





2) Tighten the front sub-frame bolts to the specified torque.

Tightening Torque: 50 N~m (5.0 kgf-m, 36.8 ft-lb)

3) Replace both LH and RH front arm assemblies.





a) Remove the front stabilizer link and ball joint from the front arm.





b) Remove the bolts and remove the front arm.

c) Install the new front arm assemblies and using the supplied new hardware, temporarily tighten the bolts and nuts.

Note:
DO NOT torque the bolts at this time. They must be tightened with the vehicle on level ground at curb height and weight.

d) Install the ball joint into the housing and torque the ball joint bolt.

CAUTION:
Before tightening, make sure the lower side of the housing and the stepped section of the ball joint are in contact.

e) Replace the front stabilizer bar bushings.





i) Remove the front stabilizer bracket and remove the bushings.

ii) Install the new bushings with the opening toward the front of the vehicle.

iii) Install the stabilizer brackets and tighten to the specified torque.

Tightening Torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)





CAUTION:
The stabilizer bracket has a set orientation. Install it with the arrow pointing toward the front of the vehicle.

f) Using new flange nuts, install the stabilizer link to the front arm.

Tightening Torque: 60 N~m (6.1 kgf-m, 44.3 ft-lb)

4) Reposition rear differential cross member.





a) Loosen the rear differential member mounting nuts (A).





b) Reposition the differential assembly downward to the lower portion of the mounts.

c) Using new self locking nuts, tighten the differential mounting nuts to the specified torque.

Tightening Torque: 110 N~m (11.2 kgf-m, 81.1 ft-lb)

5) Install rear sub-frame support bracket spacers and bushing inserts.

a) Remove only the left sub-frame support bracket and bolts.





CAUTION:
DO NOT remove both the right and left side brackets at the same time, otherwise the sub-frame can drop or alignment readings can be changed.

b) Insert the rear sub-frame mount bushing insert into the vacant side of the sub-frame mount bushing. Be sure that the bushing insert is fully seated in the bushing; it should be flush when fully inserted.





Note:
There may be some excess or residual rubber inside the vacancy for the insert. If the insert does not fully seat in the bushing, use a flat blade screw driver to break free the residual rubber.





c) Install the rear sub-frame support bracket spacer (between the vehicle body and the sub-frame support bracket) and the sub-frame mount spacer (between the rear sub-frame mount and the rear sub-frame support bracket.)

d) Using new hardware where required, install the rear sub-frame support bracket and tighten the bolts to the specified torque.

T1:Tightening Torque: 200 N~m (20.4 kgf-m, 147.5 ft-lb)

T2: Tightening Torque: 70 N~m (7.1 kgf-m, 51.6 ft-lb)

Note:
The chassis/hardware kit is applicable to both Legacy and Outback models. However, Legacy models use shorter length rear sub-frame bolts than Outback models. Make sure to compare the bolts that you removed from the vehicle you're working on with the ones supplied to ensure the correct bolts are being used. The extra 4 bolts should be discarded.

6) Repeat the above steps (a through d) on the right side sub-frame support bracket.

7) One at a time, remove the two remaining rear sub-frame lower stoppers from the mounts.

CAUTION:
DO NOT remove both the right and left side at the same time, otherwise the sub-frame may drop or alignment readings can be changed.

a) Insert the rear sub-frame mount bushing insert into the vacant side of the sub-frame mount bushing. Be sure that the bushing insert is fully seated in the bushing; it should be flush when fully inserted.





Note:
There may be some excess or residual rubber inside the space for the insert. If the insert does not fully seat in the bushing, use a flat blade screwdriver to break free the residual rubber.

b) Install the rear sub-frame mount spacer and reinstall the rear sub-frame lower stopper using new hardware. Torque the new bolt.

T1: Tightening Torque: 200 N~m (20.4 kgf-m, 147.5 ft-lb)

8) Install wheel and tire assemblies according to the RFV readings. The lowest RFV on the left front, 2nd lowest on the right front, 3rd lowest on the left rear and the highest reading on the right rear.

9) Lower the vehicle, reconnect the negative battery cable, A/F and oxygen sensor connectors, and reprogram radio stations.





10) Move the vehicle to an alignment rack or four post lift. With the vehicle at curb height, torque the front arm bushing bolts.

T1: Tightening Torque: 95 N~m (9.7 kgf-m, 70.1 ft-lb)

T2: Tightening Torque: 140 N~m (14.3 kgf-m, 103.3 ft-lb)

11) Adjust alignment as needed to ensure steering wheel is straight.

12) Install engine under cover.

13) Road test and verify repair has been completed.