(1)

Remove strut mounting bolts from steering knuckle.

(2)

Measure the gap (A) of the steering knuckle. And then mark the enlarged limit (B) to the chisel.

NOTE: Use the appropriate hammer if necessary during removal of the steering knuckle.

A

B

CF100AF0AA00USA

Marking

Enlarged limit (B) = gap (A) + 2.5 mm (0.098 in)
NOTE:
Standard of gap: 6.9 ± 0.5 mm (2.56 ± 0.02 in)

4/2/2025

10 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

10
(3)

Enlarge the gap of the steering knuckle with the chisel (A) (commercial service tool) not to surpass a limit as shown in the figure.

A

CF100AF1AA00USA
CAUTION:
•

Never enlarge the gap more than 2.5mm (0.098in).

•

Be careful not to damage the projection

and strut assembly

with the chisel.

CF100AF2AA00USA
(4)

Separate the connection of strut assembly and steering knuckle.

CAUTION:
•

Never place drive shaft joint at an extreme angle.

•

Be careful not to overextend slide joint.

•

Never allow drive shaft to hang down without support for joint sub-assembly, shaft and the other parts.

•

Be sure to remove lubricants if lubricant has been used to separate the connection of strut assembly and steering knuckle.

14.Remove mounting bolt of mounting insulator, and then remove strut assembly.

4/2/2025

11 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

11

INSTALLATION
Note the following, and install in the reverse order of removal.

Strut Assembly
•

When installing strut assembly to the vehicle, set the mounting insulator to the direction shown in the figure.

CF100AGWAA00USA

: Vehicle front

CAUTION:
Never reuse strut mounting nut.

•

Perform final tightening of fixing parts at the vehicle installation position (rubber bushing), under unladen conditions with tires on level ground.

•

Perform inspection after installation. Refer to InspectionFRONT COIL SPRING AND STRUT.

•

After replacing the strut, always follow the disposal procedure to discard the strut. Refer to FRONT COIL SPRING AND STRUT.

Strut Assembly and Steering Knuckle Connection
CAUTION:
Be sure to remove lubricants if lubricant has been used to separate the connection of strut assembly and steering knuckle.

Install the steering knuckle to strut assembly as follows.
1.Set suitable jack under steering knuckle.
2.Align the gap

of steering knuckle to the projection part

of strut.

CF100AF9AA00USA
3.Tighten the mounting bolt with pushing up the steering knuckle

4/2/2025

until contacts stopper bracket

end face, using a suitable jack.

12 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

12

CF100AFAAA00USA
CAUTION:
Check the stable condition when using a jack.

Disassembly and Assembly
DISASSEMBLY
CAUTION:
Never damage strut assembly piston rod when removing components from strut assembly.

1.Install strut attachment (A) (SST: ST35652000) to strut assembly and secure it in a vise.

A
CF100AGXAA00USA
CAUTION:
When installing the strut attachment to strut assembly, wrap a shop cloth around strut to protect from damage.

2.Using a spring compressor (A) (commercial service tool), compress coil spring between spring upper seat and lower seat (strut assembly) until coil spring with a spring compressor is free.

A

CF100AGYAA00USA
CAUTION:
Be sure a spring compressor is securely attached to coil spring. Compress coil spring.

3.Check coil spring with a spring compressor between spring upper seat and lower seat (strut assembly) is free. And then remove piston rod lock nut while securing the piston rod tip so that piston rod
does not turn.
4.Remove mounting insulator, mounting bearing, upper rubber seat and bound bumper from strut.

4/2/2025

13 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

13

5.After removing coil spring with a spring compressor (commercial service tool), then gradually release a spring compressor.
CAUTION:
Loosen while making sure coil spring attachment position does not move.

6.Remove lower rubber seat.
7.Remove strut attachment (A) (SST: ST35652000) from strut.

A
CF100AGXAA00USA
8.Perform inspection after disassembly. Refer to InspectionFRONT COIL SPRING AND STRUT.

ASSEMBLY
CAUTION:
Never damage strut assembly piston rod when installing components from strut assembly.

1.Install strut attachment (SST: ST35652000) to strut and secure it in a vise.
CAUTION:
When installing the strut attachment to strut assembly, wrap a shop cloth around strut to protect from damage.

2.Install lower rubber seat with its protrusion

on the lower area aligned with the hole

on the strut.

CF100AGZAA00USA

4/2/2025

14 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

14

3.Compress coil spring using a spring compressor (commercial service tool), and install it onto strut assembly.
CAUTION:
•

Be sure a spring compressor is securely attached to coil spring, before compress coil spring.

•

Align the lower end of coil spring

with lower rubber seat

as shown in the figure.

A

CF100AH0AA00USA
Dimension (A)
•

: 5 mm (0.20 in) or less

Set coil spring so that its paint marks are aligned with the position from the bottom end of the coil spring as shown in the figure.

CAUTION: On the new front coil spring for Outlander, there are two side by side paint markings. Please install the
front coil spring so that the paint markings are located at 1.25 turns from the bottom end.

NEW paint marks

OLD paint marks
DF100AH1AA00USA

: Upper side

Japan production MODELS
: 1.25 turns

4.Apply soapy water to bound bumper.
CAUTION:
Never use machine oil.

5.Set bound bumper to piston rod of strut.
6.Install mounting bearing, mounting insulator and upper rubber seat on to spring.
CAUTION:
Never apply oils, such as grease, when installing the mounting bearing and mounting insulator.

4/2/2025

15 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

15

7.Set the mounting insulator to the direction shown in the figure, and then install the mounting insulator, the upper rubber seat and the mounting bearing to the strut.

CF100AGWAA00USA

: Vehicle front

CAUTION:
•

Align the upper end of coil spring

with upper rubber seat

as shown in the figure.

A

Upper end of coil spring
at upper rubber seat

Dimension (A)

CF100AH2AA00USA

Lower end of coil spring at
lower rubber seat

: 5 mm (0.20 in) or less

8.Secure piston rod tip so that piston rod does not turn, then tighten piston rod lock nut with specified torque.
CAUTION:
Never reuse piston rod lock nut.

9.Gradually release a spring compressor (A) (commercial service tool), and remove coil spring.

A

CF100AGYAA00USA
CAUTION:
Loosen while making sure coil spring attachment position does not move.

4/2/2025

16 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

16
10.Remove the strut attachment (A) (SST: ST35652000) from strut assembly.

A
CF100AGXAA00USA

Inspection
INSPECTION AFTER DISASSEMBLY
Check the following items, and replace the parts if necessary.

Strut
•

Strut for deformation, cracks or damage

•

Piston rod for damage, uneven wear or distortion

•

Oil leakage

Strut Mounting Insulator and Bound Bumper
Check strut mounting insulator and bound bumper for cracks, wear or damage.

Coil Spring
Check coil spring for cracks, wear or damage.

INSPECTION AFTER INSTALLATION
1.Check wheel sensor harness for proper connector. Refer to FRONT WHEEL SENSOR.
2.Check wheel alignment. Refer to WHEEL ALIGNMENT.
3.Adjust neutral position of steering angle sensor. Refer to DescriptionADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION.

Disposal
1.Set strut assembly horizontally to the ground with the piston rod fully extracted.
2.Drill 2 – 3 mm (0.08 – 0.12 in) hole at the position (

) from top as shown in the figure to release gas gradually.

A

CF100AH3AA00USA

4/2/2025

17 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

17

CAUTION:
•

Wear eye protection (safety glasses).

•

Wear gloves.

•

Be careful with metal chips or oil blown out by the compressed gas.

NOTE:
•

Drill vertically in this direction show by arrow.

•

Directly to the outer tube avoiding brackets.

•

The gas is clear, colorless, odorless, and harmless.

A

: 20 – 30 mm (0.79 – 1.18 in)

3.Position the drilled hole downward and drain oil by moving the piston rod several times.
CAUTION:
Dispose of drained oil according to the law and local regulations.

4/2/2025

18 of 26

(5239/TSL22006033I)

FRONT SUSPENSION

18

TRANSVERSE LINK
Exploded View
SEC. 401

155 (15.8, 114)

175 (17.8, 129)