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2006 XT
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671 Posts
Discussion Starter #1
Welp, I've struck out looking for the SF.com thread that had some insight on the install. I'm downloading (twenty pdf per hr from techinfo.subabru.com) the fsm as I type. Doesn't seem like rocket science :roll:

Seems like I have to pull the hub bolt out from both lateral links to attach the box??? The fsm states I have to remove the trailing arm to get the lateral bolt out???

I recall the sf.com post saying it was hard to align the laterals to get the 10" bolt back on???

I'll probably do the install this weekend.

I'll take pics and get the install steps onto scoobymods.

Jeff 06 FXT
 

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2006 XT
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671 Posts
Discussion Starter #4
I'll email Poltec with these questions:

The set screw. Does it need any threadlock?
Does the box sit square on the hub tight?
Does the box pivit and use the set screw the adjust how it sits?
Does the washer sit inside or outside the box?
 

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Premium Member
04 XT
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733 Posts
The suspension height of the Forester makes it prone to break stock and even upgraded components when adding upgraded rear swaybars(stabilizer bars). Even STi rear bars have broken endlinks and ripped the endlink mounts off of stock lateral links.

I have gone through my share of breakage, walking bars, torn endlinks grease fittings and bent endlinks. Finally the mounts broke off of the lateral link.






 

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Premium Member
04 XT
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733 Posts
So that's the problem now there are a couple of solutions:

1) get a new rear lateral link and go back to stock sway
2) get STi or aftermarket lateral links and pay a lot and be very careful with bar width
3) find a way to reinforce stock welds before they break
4) change to hub mounted endlinks;)

http://www.poltec.us/products/subaru/suspension/rear_end_links/1a-df016.htm

This install isn't for everyone, don't do it unless you're competant and don't sue me in any case. Your liability is your own. And my observations don't replace a good shop manual;)

Tools needed:
eye protection
metric wrenches and socket set
hex head wrench
torque wrench capable of greater than 110 ft-lb
jack and 2 jack stands

Optional tools:
penetrating lubricant "PB blaster" is my choice
air tools are nice impact wrench, die grinder, cut off wheel
sawzall
black spray paint
 

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Premium Member
04 XT
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733 Posts
Do the obvious:
loosen sway bar bolts
raise the car remove wheels
push bar out of the way

Now there is a decision, you can keep the rear lateral links as they are by removing them from the differential carrier and flipping them upside down or you can remove the mount tabs. I chose the latter because one was already gone.

Using a Sawzall I removed the other mount completely and ground it down perfectly then blew a seal on my die-grinder and had a ragged nasty weld left on the right lateral arm.



 

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04 XT
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733 Posts
After dealing with the lateral arms you then have to deal with the hub. One side at a time.

Support the hub with the jack.
Remove the very large and highly torqued bolt bolt that runs through the lateral links and hub careful to keep the arms in alignment if you can.
If you are going to flip the rear lateral link do it now. Torque is 74 ft-lbs. to the crossmember.
Put the box ends on.
You must use the supplied thin washers or it won't go back together.
Tighten the hex head set screw to PolTec spec(I couldn't get a torque wrench on it)
Torque the hub bolt to gasp 103(ft-lb)



 

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Premium Member
04 XT
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733 Posts
After doing both sides, replace wheels lower to the ground and tighten endlinks to the stabilizer bar. Torque is 33 ft-lbs.

Note that I have an early Hotchkis STi bar with a not so compatible width. So I run my bar with the endlinks on the inside. Be careful if you take the fittings apart that you get them back in the right order. Some of them are aluminum and are very maleable. As I discovered and had to replace an insert.



 

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Premium Member
04 XT
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733 Posts
Take it in for an alignment ASAP. My toe was out by .25" and I kept the links very stable and didn't flop the rear link.


I've had these on for close to year and they remain perfect. If only I didn't have to lube the front sway every 6 months I would now be totally satisfied with the stabilizer bars.
 

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2006 XT
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671 Posts
Discussion Starter #11
Thanks for the Install notes. Couple quick questions:

Could the original endlink mounts on the laterals "NOT" be removed. They don't look like they would be in the way and would make "going back to stock" an option. I've no grinder or sawzall. Yes it's getto:rolleyes:

Do you recall the tq on the box set screw. And what's its purpose. Does the box have play to rotate?

Again thanks bigtime:cool:
 

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Premium Member
2004 Forester XT MT
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1,433 Posts
wagn said:
Could the original endlink mounts on the laterals "NOT" be removed. They don't look like they would be in the way and would make "going back to stock" an option.
You can just flip the lateral links over so the mounting tabs point down.
 

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2006 XT
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671 Posts
Discussion Starter #13
Thinking out loud. "I wonder if both ends of the laterals are the same size on both ends?"

If I flip the laterals they still may rub the boxlink. If Eclispe had a photo of the gap btwn the lateral and the endlink I would be certian. If you didn't grind down the weld would it have rubbed the endlink? If I put the inside where the outside was I could flip or not???

Here's a pic. Seems Dariusz is using some different parts. And my box seems a bit less rectangle.

 

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Premium Member
2004 Forester XT MT
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1,433 Posts
Those end links look better. I like the rubber boots but I wonder if they will make a difference?

The lateral links have different bushings at each end. If you flip them with the tabs inboard you should consider swapping the bushings, too.

If you do decide to cut your mounts let me know. I'll sell my stock lateral links if your worried about going back to stock.
 

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Premium Member
04 XT
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733 Posts
wagn said:
Thanks for the Install notes. Couple quick questions:

Could the original endlink mounts on the laterals "NOT" be removed. They don't look like they would be in the way and would make "going back to stock" an option. I've no grinder or sawzall. Yes it's getto:rolleyes:

Do you recall the tq on the box set screw. And what's its purpose. Does the box have play to rotate?

Again thanks bigtime:cool:
If you look at post #8 you get an idea of where the endlink is in relation to the lateral link mount. It will hit. The old site had a member who did the same install and showed the flipped link.

Please contact Dariusz at PolTec for the torque spec on the set screw. I don't have it anymore. Yes the set screw locates the box on the hub and prohibits any wandering that could possibly occur with vibration from wheel movement. I don't think it would move much against the torque on the big bolt but I don't want to find out.
 

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Premium Member
2004 Forester XT MT
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1,433 Posts
When I had the pol-tec's I flipped my lateral links to accomodate them. This was also the time when I unknowingly had the STi COBB rear sway bar. The endlink is attached to the inside of the bar as a result. In hindsight, having the wrong bar is what caused the pol-tec end links to fail.

 

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88 Posts
my poltec setup has been working perfectly. i installed the box mounted end links over a year ago - and have not had any problems.

here are my install pix

my car was on jack stands to start. when it came time to remove the stock end links and connect the poltec end links - i lowered the car onto a set of rhino ramps.

i started with the passenger side.





then i went to the driver's side.



it was at this point that i realized that i would have trouble with the lateral links...



so i went back to the passenger side - and flipped the trailing lateral link.



and then flipped the driver's side link...



another shot of the passenger side:



and the driver's side...



i got an alignment when i was done...

...and i plan on having the poltec lateral link set installed very soon. ;)

 

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2006 XT
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671 Posts
Discussion Starter #18
Eww, Post#16 shows me that the two ends of the lateral are the same and with the endlink facing down. That's the way I'll do it. I'll test with the mount facing up to start.

Thanks to all who have contributed to this thread.
 

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2005 XT
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923 Posts
I got my box endlinks in but one of the holes is bigger than the other on the part that attaches to the lateral link! Looks like a slight manufacturing defect, do you guys think it will be ok to install or get it replaced? Does the "box" part make the fit snug so the hole really just keeps it there?
 
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