1996 SUBARU LEGACY clutch

B2M0173A
B: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent when servicing the clutch.
1) Check the bearing for smooth movement by applying
force in the radial direction.
Radial direction stroke:
FWD; Approx.
1.0 mm (0.039 in)
AWD; Approx.
1.4 mm (0.055 in)
G2M0240
2) Check the bearing for smooth rotation by applying pres-
sure in the thrust direction.
3) Check wear and damage of bearing case surface con-
tacting with lever.
G2M0241
2. RELEASE LEVER
Check lever pivot portion and the point of contact with
release bearing case for wear.
C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the following
points with a light coat of grease.
Inner groove of release bearing
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease contain-
ing molybdenum disulphide.)
6
2-10SERVICE PROCEDURE
3. Release Bearing and Lever

B2M0633A
1. MECHANICAL APPLICATION TYPE
1) While pushing release lever

3to pivot and twisting it to
both sides, fit retainer spring

5onto the constricted portion
of pivot.
NOTE:
Confirm that retainer spring is securely fitted by observing
it through the main case hole.
2) Install release bearing

6and fasten it with two clips
2.
3) Install release lever seal

4.
G2M0235
4) After remounting engine and transmission on body,
make adjustment of the clutch release lever end play.
CAUTION:
Take care not to twist the cable during adjustment.
5) Install release lever return spring (Models without hill
holder only).
NOTE:
Hook up the return spring to right side hole of the release
lever.
G2M0242
4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either clutch cover or clutch
disc.
G2M0243
3) Remove flywheel.
7
2-10SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover

B2M0328
B: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of facing.
Replace if facings are worn locally or worn down to less
than the specified value.
Depth of rivet head:
Standard value
1.3—1.9 mm (0.051—0.075 in)
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning fluid.
B2M0329A
2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace clutch disc and inspect transmission front oil seal,
transmission case mating surface, engine rear oil seal and
other points for oil leakage.
B2M0330A
4) Deflection on facing
If deflection exceeds the specified value at the outer cir-
cumference of facing, repair or replace.
Limit for deflection:
1.0 mm (0.039 in) at R = 107 mm (4.21 in)
B2M0333A
5) Worn spline, loose rivets and torsion spring failure
Replace defective parts.
8
2-10SERVICE PROCEDURE
4. Clutch Disc and Cover

G2M0248
2. CLUTCH COVER
Visually check for the following items without
disassembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at center of
diaphragm spring.
G2M0249
3) Damaged or worn disc contact surface of pressure
plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.
G2M0250
3. FLYWHEEL
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent.
1) Damage of facing and ring gear
If defective, replace flywheel.
G2M0251
2) Smoothness of rotation
Rotate ball bearing applying pressure in thrust direction.
If noise or excessive play is noted, replace ball bearing as
follows:
(1) Drive out ball bearing from flywheel.
(2) Press bearing into flywheel until bearing end sur-
face is flush with clutch disc contact surface of flywheel.
Do not press inner race.
ST 899754112 SNAP RING PRESS
9
2-10SERVICE PROCEDURE
4. Clutch Disc and Cover

B2M0331A
B2M0332A
C: INSTALLATION
1) Install flywheel.
2) Install ST, and tighten the flywheel attaching bolts to the
specified torque.
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72±3 N⋅m (7.3±0.3 kg-m, 52.8±2.2 ft-lb)
NOTE:
Tighten flywheel installing bolts gradually. Each bolt should
be tightened to the specified torque in a crisscross fashion.
G2M0253
3) Insert ST into the clutch disc and install them on the
flywheel by inserting the ST end into the pilot bearing.
ST 499747100 CLUTCH DISC GUIDE
G2M0254
4) Install clutch cover on flywheel and tighten bolts to the
specified torque.
NOTE:
When installing the clutch cover on the flywheel, position
the clutch cover so that there is a gap of 120°or more
between“0”marks on the flywheel and clutch cover. (“0”
marks indicate the directions of residual unbalance.)
Note the front and rear of the clutch disc when installing.
Tighten clutch cover installing bolts gradually. Each bolt
should be tightened to the specified torque in a crisscross
fashion.
Tightening torque:
15.7±1.5 N⋅m (1.6±0.15 kg-m, 11.6±1.1 ft-lb)
5) Remove ST.
ST 499747100 CLUTCH DISC GUIDE
10
2-10SERVICE PROCEDURE
4. Clutch Disc and Cover

1. Engine Cooling System
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.

h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.

k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.
20
2-5DIAGNOSTICS
1. Engine Cooling System

1. Clutch System
A: SPECIFICATIONS
2200 cc
Clutch cover Diaphragm set load kg (lb) 450 (992)
Clutch discFacing material Woven
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
Spline O.D. mm (in)
(No. of teeth)25.2 (0.992)
(24)
Clutch release lever ratio 3.0
Release bearing Grease-packed self-aligning
B: SERVICE DATA
2200 cc
Clutch pedal Full stroke mm (in) 140 — 150 (5.51 — 5.91)
Release
leverStroke mm (in) 24 — 26 (0.94 — 1.02)
Play at release lever center mm (in) 3 — 4 (0.12 — 0.16)
Clutch discDepth of rivet head mm (in)Standard 1.3 — 1.9 (0.051 — 0.075)
Limit of sinking 0.3 (0.012)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)
2
2-10SPECIFICATIONS AND SERVICE DATA
1. Clutch System

1. Clutch System
B2M0632A

1Clutch cable bracket


2Clutch release lever sealing


3Retainer spring


4Pivot


5Clutch release lever


6Clip


7Clutch release bearing


8Clutch cover

9Clutch disc


10Return spring (Models without hill holder only)


11Clutch return spring bracket
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 15.7±1.5 (1.6±0.15, 11.6±1.1)
3
2-10COMPONENT PARTS
1. Clutch System