Strut Replacement on a Subaru 2001 Legacy GT

The 2001 Subaru Legacy GT came with a 2.5-liter four-cylinder engine and a five-speed manual or four-speed automatic transmission. The front suspension on your Legacy has two MacPherson type struts, one for each wheel. To replace either strut you will have to remove the strut and coil spring assembly from the vehicle and disassemble it. The coil springs are highly compressed and held under extreme pressure, so special tools are required safely perform this repair. It is recommended to replace both front struts at the same time for optimal ride quality.

Instructions

Removal

1

Park the vehicle on a level surface and set the parking brake. Loosen the lug nuts for the wheel to be serviced with a lug wrench. Lift the front of the vehicle into the air with a floor jack and place jack stands under the front sub-frame rails. Lower the vehicle until it rests securely on the jack stands.

2

Remove the lug nuts followed by the wheel and tire. Remove the bolt securing the rubber brake hose to the strut assembly with a socket and ratchet. Remove the bolt securing the wheel speed sensor harness. Remove the lower strut mounting nuts with a socket and ratchet; use a wrench to prevent the bolts from rotating.

3

Lift the vehicle hood and support it with the hood prop rod. Remove the three nuts securing the upper strut mount to the strut tower. Push the strut assembly away from the steering knuckle and lower it away from the vehicle. Tap the strut with a rubber mallet and support it by hand if it is seized to the steering knuckle.

Disassembly and Reassembly

4

Place the base of the strut in the vise and tighten the vise. Install the spring compressor arms over the coil springs and the top most and bottom most coil; the spring compressors should be 180 degrees away from each other. Tighten the spring compressor bolts one turn at a time, alternating back and forth until the spring is compressed enough to move freely.

5

Place a wrench over the strut piston rod and onto the securing nut. Place an allen wrench into the hole at the top of the strut rod. Loosen the strut rod nut with a wrench while holding the rod steady with the allen wrench. Remove the strut rod nut and remove the upper strut mount. Remove the coil spring and lower spring bushing from the strut. Remove the spring helper and dust cover. Dispose of the old strut, strut mount, and strut rod nut.

6

Set the new strut upright and hold it in place. Push down on the strut rod until it is halfway through its entire stroke. Holding the strut rod attempt to move it up and down, if there is more the 10 mm or .39-inches of play follow the next step. If the strut rod does not freely move, skip the next step.

7

Hold the strut upside down with the strut rod fully extended. Fully contract the piston rod several times to purge any air pockets inside the strut. Once this process is complete the strut must always face upward as it is installed in the vehicle, or air may enter the strut and sacrifice ride quality.

8

Mount the new strut upright in the vise and tighten the vise. Place the lower strut bushing onto the spring seat followed by the spring helper and strut rod dust cover. Set the original coil spring onto the new strut; make sure the flat end of the coil spring faces upward.

9

Place the upper spring bushing onto the coil spring followed by the spring seat. The three outside holes of the spring seat should face the same direction of the lower mounting flanges. Set the new upper strut mount onto the coil spring so that the strut rod extends through the center of the mount. Install the new strut rod locking nut hand tight.

10

Tighten the new strut rod nut a full three turns with a wrench, using an allen wrench to prevent the strut rod from rotating. Loosen the spring compressor bolts one turn at a time alternating back and forth until the spring compressors are loose. Remove the coil spring compressors from the coil spring. Tighten the strut rod nut with a torque wrench, crowfoot attachment and allen wrench. Remove the strut assembly from the vise.

Installation

11

Lift the strut assembly into the strut tower and push the strut mount studs through the strut tower holes. Loosely install the upper strut mount nuts. Pull the lower strut flanges over the the steering knuckle and push the lower strut bolts through the strut and knuckle. Install new lower strut mounting lock nuts hand tight.

12

Tighten the upper strut mounting nuts to 15 foot-pounds with a torque wrench. Tighten the lower strut mounting lock nuts to 116 foot-pounds, holding the bolt head steady with a wrench. Install the wheel speed sensor harness to the new strut and tighten the nut to 24 foot-pounds. Install the rubber brake hose to the the new strut and tighten the nut to 24 foot-pounds. Repeat the entire process for the opposite side of the vehicle if necessary.

13

Place the wheel and tire onto the vehicle and install the lug nuts hand tight. Lift the front of the vehicle off the jack stands and remove the jack stands. Lower the vehicle to the ground. Tighten the lug nuts to 58-72 foot-pounds in a criss cross pattern. Shut the vehicle hood.