Download Subaru Legacy & Outback 2010 Service & Repair Manual –

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Repairing the suspension crossmember on a Subaru Legacy Outback involves several steps, and I’ll guide you through the process step-by-step. Before we begin, make sure you have safety gear, tools, and parts ready. Here’s a breakdown of what you need to know and do.

### Safety First:
1. **Wear Safety Gear**: Use safety glasses and gloves to protect yourself.
2. **Work in a Safe Environment**: Make sure you’re in a well-ventilated area and have a flat, stable surface to work on.
3. **Use Proper Lifting Equipment**: If you need to lift the vehicle, use a hydraulic Jack and Jack stands to secure it. Never work under a vehicle supported only by a jack.

### Tools and Materials:
– **Tools**:
– Socket set (metric, as Subaru typically uses metric sizes)
– Wrenches (again, metric)
– Ratchet
– Torque wrench
– Screwdrivers (flathead and Phillips)
– Hammer (rubber mallet if possible)
– Prying tool (like a crowbar)
– Jack and Jack stands
– Brake cleaner or degreaser
– Wire brush
– Safety goggles and gloves

– **Materials**:
– Replacement crossmember (if damaged)
– New bolts and nuts (if needed)
– Anti-seize compound (optional)
– Lubricant (like WD-40)

### Steps to Repair the Suspension Crossmember:

#### Step 1: Preparation
1. **Disconnect the Battery**: Open the hood and disconnect the negative battery terminal to prevent any electrical shorts.
2. **Lift the Vehicle**: Use the hydraulic Jack to lift the front of the vehicle. Secure it with Jack stands under the manufacturer-recommended lift points.

#### Step 2: Remove front Components
1. **Remove the Wheels**: Use a lug wrench to loosen and remove the lug nuts. Take off the front wheels to gain access to suspension components.
2. **Disconnect Suspension Components**:
– Locate the lower control arms, struts, and any other parts connected to the crossmember.
– Use the socket set to remove bolts that connect the control arms to the crossmember. Make sure to keep track of any washers or spacers.
– Depending on the design, you may also need to disconnect the sway bar if it connects to the crossmember.

#### Step 3: Remove the Old Crossmember
1. **Locate Crossmember Bolts**: Find the bolts securing the crossmember to the vehicle’s frame.
2. **Remove Bolts**: Use the socket set to remove these bolts. If they’re rusted or stuck, you may need to use penetrating oil. Allow it to soak for a few minutes before attempting to loosen them.
3. **Support the Crossmember**: Once all the bolts are removed, support the crossmember with your hands or a jack, then gently lower it down and remove it from the vehicle.

#### Step 4: Install New Crossmember
1. **Clean the Area**: Remove any rust or dirt from the area where the crossmember sits using a wire brush and brake cleaner.
2. **Position the New Crossmember**: Carefully lift the new crossmember into position. Align it with the bolt holes on the frame.
3. **Install Bolts**: Insert the bolts through the crossmember into the frame. download Subaru Legacy Outback workshop manual Hand-tighten them first to keep the crossmember in place.
4. **Torque Bolts**: Using a torque wrench, tighten the bolts to the manufacturer’s specified torque (you can find this in a repair manual or online). This ensures they are securely fastened without being over-tightened.

#### Step 5: Reconnect Suspension Components
1. **Reconnect Lower Control Arms**: Align the control arms back to their original position and insert the bolts. Hand-tighten first, then torque to specification.
2. **Reconnect Sway Bar**: If you disconnected the sway bar, reconnect it now.
3. **Reattach Struts**: Make sure to reconnect any struts or suspension components that were disconnected.

#### Step 6: reinstall Wheels and Lower Vehicle
1. **Reinstall Wheels**: Place the wheels back onto the hubs and hand-tighten the lug nuts.
2. **Lower the Vehicle**: Carefully remove the Jack stands and lower the vehicle using the hydraulic jack.
3. **Tighten Lug Nuts**: Once the vehicle is on the ground, use the lug wrench to tighten the lug nuts in a criss-cross pattern to ensure even tightening.

#### Step 7: Final Checks
1. **Reconnect Battery**: Reconnect the negative terminal of the battery.
2. **Inspect Your Work**: Look over everything to ensure all bolts are tight, and nothing is out of place.
3. **Test Drive**: Take the vehicle for a test drive at low speeds to ensure everything feels right. Listen for any unusual noises.

### Conclusion
Congratulations! You’ve just repaired the suspension crossmember on your Subaru Legacy Outback. Always remember to consult your vehicle’s manual for specific torque specifications and procedures. If you encounter anything you’re unsure about, don’t hesitate to seek help from a more experienced mechanic or a professional. Happy wrenching!
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