2005 Subaru Outback RFACTORY OEM SERVICE PROCEDURE

Front Axle: Installation

WARNING: This page is about a different car, the 2005 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. While aligning alignment mark on camber adjusting bolt head, connect housing and strut.
    CAUTION: When self-locking nut is removed, replace it with new one.

    Tightening torque: 

    177 N.m (18.0 kgf-m, 130 ft-lb) 

  2. Install front drive shaft. < Ref. to , INSTALLATION , Front Drive Shaft. >
  3. Install transverse link ball joint to housing.

    Tightening torque: 

    49 N.m (5.0 kgf-m, 36 ft-lb) 

  4. Install ABS sensor harness on strut.
  5. Install ABS sensor on housing.

    Tightening torque: 

    32 N.m (3.3 kgf-m, 23.9 ft-lb) 

  6. Install disc rotor on hub.
  7. Install disc brake caliper on housing.

    Tightening torque: 

    78 N.m (8 kgf-m, 57.9 ft-lb) 

  8. Connect stabilizer link.
  9. Install tie-rod end.

    Tightening torque: 

    27.0 N.m (2.75 kgf-m, 19.9 ft-lb) 

    CAUTION: Do not hammer the bottom of tie-rod end when installing it.
  10. After tightening castle nut to specified torque, retighten it further within 60° until a slot in castle nut is aligned with the ball joint hole. Insert cotter pin, and then bend the cotter pin around castle nut to secure it.
    Fig 1: Locating Castle Nut And Inserting Cotter Pin
    G03751620Courtesy of SUBARU OF AMERICA, INC.
  11. While depressing brake pedal to prevent front drive shaft from turning, tighten axle nut to specified torque.

    Tightening torque: 

    220 N.m (22 kgf-m, 162 ft-lb) 

    CAUTION:
    • When axle nut is removed, replace it with new one.
    • Always tighten axle nut before installing wheel on vehicle.
    • Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing.
  12. After tightening axle nut, lock it securely.
    Fig 2: Locking Axle Nut
    G03751621Courtesy of SUBARU OF AMERICA, INC.
  13. Install wheel and tighten wheel nuts to specified torque.

    Tightening torque: 

    88 N.m (9 kgf-m, 65 ft-lb) 

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.