Repairing the suspension strut tower on a Subaru Legacy involves several steps and a number of components. click here for more details on the download manual…..
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The strut tower is part of the unibody structure of the car, typically located at the front and rear where the strut assembly connects to the body. If the strut tower is damaged or rusted, it may need repair to ensure proper suspension function and vehicle safety. Below is a detailed guide on how to perform this repair.
### Tools and Materials Needed:
– **Tools:**
– socket set (including ratchet and extensions)
– Wrenches (including torque wrench)
– Screwdrivers (flathead and Phillips)
– Pry bar
– Hammer
– Cutting tool (grinder or saw)
– Drill with metal bits
– Spot weld cutter (if needed)
– Sockets for strut assembly bolts
– Jack and jack stands
– safety glasses
– Gloves
– **Materials:**
– Replacement strut tower (if severely damaged)
– Sheet metal (if fabricating)
– Welding rod or MIG wire (if welding)
– Rust-proof paint
– Primer
– Body filler (if needed)
### Steps for Suspension Strut Tower Repair:
#### 1. **Preparation**
– **Safety First:** Park the vehicle on a level surface and engage the parking brake. Wear safety glasses and gloves.
– **Disconnect the Battery:** Disconnect the negative terminal of the battery to prevent any electrical issues.
– **Remove the Wheel:** Use a jack to lift the front or rear of the vehicle (depending on the strut tower being repaired) and secure it with jack stands. Remove the wheel using a lug wrench.
#### 2. **Access the Strut Tower**
– **Remove Components:** Depending on the access needed, you may need to remove components like the fender liner, air intake, or other obstructions that cover the strut tower. Use the appropriate tools to unbolt and remove these parts carefully.
#### 3. **Inspect the Strut Tower**
– **Assess Damage:** Examine the strut tower for rust, cracks, or physical damage. If it’s only surface rust, it may just need to be cleaned and treated. If the damage is severe (such as a large hole or structural weakness), you will need to replace the tower or fabricate a repair panel.
#### 4. **Preparing for Repair**
– **Cut Out Damaged Area:** If the strut tower is rusted or damaged beyond repair, use a cutting tool to remove the affected section. Be cautious not to damage surrounding areas.
– **Fabricate a Patch Panel (if necessary):** If you’re crafting a new section, measure the dimensions of the cut-out area. Cut a piece of sheet metal to size, ensuring it overlaps onto solid metal.
#### 5. **Welding the New Section**
– **Position the New Panel:** place the fabricated patch into the strut tower area. Clamp it in place to prevent movement during welding.
– **Weld the Patch:** Use a MIG welder or stick welder to attach the new section to the strut tower. Ensure proper penetration and coverage for a strong bond. Make sure to wear proper protective gear and follow safety protocols while welding.
#### 6. **Reinforce the Structure**
– **Reinforcement (if required):** If the strut tower was severely compromised, consider adding additional support or bracing. This can be done using additional metal brackets or plates welded in place.
#### 7. **Finishing Touches**
– **Clean
and Treat:** Grind down any rough welds for a smooth finish. Treat the area with rust-inhibiting primer and paint to prevent future corrosion. Allow it to dry completely.
– **Body Filler (if needed):** If there are imperfections in the surface, apply body filler to smooth out any rough spots. Sand it down to a smooth finish.
#### 8. **Reassembly**
– **Reinstall Components:** Reattach any components that were removed earlier (e.g., fender liners, air intake).
– **Install the Strut Assembly:** If the strut assembly was removed, reinstall it by following the reverse order of disassembly. Ensure all bolts are torqued to the manufacturer’s specifications.
#### 9. **Final Checks**
– **Reconnect the Battery:** Reconnect the negative terminal of the battery.
– **Reinstall the Wheel:** Put the wheel back on and lower the vehicle to the ground. Tighten the lug nuts to the proper torque specification.
– **Test Drive:** Take the vehicle for a test drive to ensure proper handling and check for any unusual noises or handling characteristics.
### Conclusion
Repairing the suspension strut tower on a Subaru Legacy is a detailed process that requires mechanical skill and safety awareness. Make sure to follow all safety procedures and consult the vehicle’s service manual for specific torque specifications and component locations. If you’re unsure about any part of the process, consider consulting a professional mechanic to ensure the repair is done correctly.
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