1999 SUBARU LEGACY Service Repair Manual

4) Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
Tightening torque:
48
±5 N´m (4.9±0.5 kg-m, 35.4±3.6 ft-lb)
S2M0157
11
[W4A0]2-9SERVICE PROCEDURE
4. Muffler

MEMO:
12
2-9SERVICE PROCEDURE

1. Clutch System
2200 cc 2500 cc
Clutch cover Diaphragm set load kg (lb) 450 (992) 550 (1,213)
Clutch discFacing material Woven
O.D.´I.D.´thickness mm (in) 225´150´3.5 (8.86´5.91´0.138)
Spline O.D. (No. of teeth) mm (in) 25.2 (0.992) (24)
Depth of rivet head mm
(in)Standard 1.3 Ð 1.9 (0.051 Ð 0.075)
Limit of sinking 0.3 (0.012)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)
Clutch release lever ratio 3.0 1.6
Release bearingGrease-packed self-aligning
Release leverStroke mm (in) 24 Ð 26 (0.94 Ð 1.02)
Play at release lever center mm (in)3 Ð 4 (0.12 Ð 0.16)
Clutch pedal Full stroke mm (in)140 Ð 150
(5.51 Ð 5.91)130 Ð 135
(5.12 Ð 5.31)
2
2-10[S100]SPECIFICATIONS AND SERVICE DATA
1. Clutch System

1. Clutch System
A: MECHANICAL APPLICATION TYPE
B2M0632C
(1) Clutch cable bracket
(2) Clutch release lever sealing
(3) Retainer spring
(4) Pivot
(5) Clutch release lever(6) Clip
(7) Clutch release bearing
(8) Clutch cover
(9) Clutch disc(10) Return spring (Models without
hill holder only)
(11) Clutch 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
[C1A0]2-10COMPONENT PARTS
1. Clutch System

B: HYDRAULIC APPLICATION TYPE
B2M1890A
(1) Operating cylinder
(2) Washer
(3) Clutch hose
(4) Bracket
(5) Clamp
(6) Pipe
(7) Master cylinder ASSY
(8) Clevis pin
(9) Snap pin(10) Lever
(11) Clutch release lever sealing
(12) Retainer spring
(13) Pivot
(14) Release lever
(15) Clip
(16) Release bearing
(17) Clutch cover
(18) Clutch disc(19) Flywheel
Tightening torque: N´m (kg-m, ft-lb)
T1:
15.7±1.5 (1.6±0.15, 11.6±1.1)
T2:18±3 (1.8±0.3, 13.0±2.2)
T3:37±3 (3.8±0.3, 27.5±2.2)
4
2-10[C1B0]COMPONENT PARTS
1. Clutch System

2. Master Cylinder and Reservoir Tank
S2M0005A
(1) Reservoir cap
(2) Reservoir tank
(3) Oil seal
(4) Straight pin
(5) Master cylinder(6) Washer
(7) Diaphragm spring
(8) Seat
(9) Return spring
(10) Piston(11) Push rod
(12) Piston stop ring
Tightening torque: N´m (kg-m, ft-lb)
T:
46.6±7.4 (4.75±0.75, 34.4±5.4)
5
[C200]2-10COMPONENT PARTS
2. Master Cylinder and Reservoir Tank

1. General
A: PRECAUTION
When servicing clutch system, pay attention to the
following items.
1. MECHANICAL APPLICATION TYPE
1) Check the routing of clutch cable for smooth-
ness.
2) Excessive tightness or looseness of clutch
cable have a bad influence upon the cable durabil-
ity.
3) Apply grease sufficiently to the connecting por-
tion of clutch pedal.
4) Apply grease sufficiently to the release lever
portion.
5) Position clutch cable through the center of toe
board hole and route it smoothly. Adjustment is
done by moving the outer cable.
6) Make sure not to let the clutch chatter when
starting forward or rearward. If clutch chattering
occurs, readjust so that the bend of clutch outer
cable becomes flatter.
2. HYDRAULIC APPLICATION TYPE
1) Check fluid level using a scale on outside of
reservoir tank. If the level is below ªMINº, add
clutch fluid to bring it up to ªMAXº.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4
brake fluid
CAUTION:
IAvoid mixing different brakes of brake fluid
to prevent degradation of the fluid.
IBe careful not to allow dirt or dust to get into
the reservoir tank.
IUse fresh DOT3 or DOT4 brake fluid when
refilling fluid.
S2M0351A
2) Make sure that brake fluid does not leak from
master cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever
pinion.
4) Check for proper clutch disengagement and
clutch pedal return ability.
2. On-car Service
A: ADJUSTMENT
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring from lever
(Models without hill holder only).
2) Adjust spherical nut so that the play is within the
specified value at the lever end (center of spheri-
cal nut).
Play:
3Ð4mm(0.12 Ð 0.16 in)
Full stroke:
24 Ð 26 mm (0.94 Ð 1.02 in)
CAUTION:
Take care not to twist the cable during adjust-
ment.
G2M0234
3) Upon completion of adjustment, securely lock
spherical nut with lock nut.
G2M0235
4) Install return spring on lever (Models without hill
holder only).
NOTE:
Hook the long hook side of the return spring with
the lever (Models without hill holder only).
6
2-10[W1A0]SERVICE PROCEDURE
1. General

1. General
A: PRECAUTION
When servicing clutch system, pay attention to the
following items.
1. MECHANICAL APPLICATION TYPE
1) Check the routing of clutch cable for smooth-
ness.
2) Excessive tightness or looseness of clutch
cable have a bad influence upon the cable durabil-
ity.
3) Apply grease sufficiently to the connecting por-
tion of clutch pedal.
4) Apply grease sufficiently to the release lever
portion.
5) Position clutch cable through the center of toe
board hole and route it smoothly. Adjustment is
done by moving the outer cable.
6) Make sure not to let the clutch chatter when
starting forward or rearward. If clutch chattering
occurs, readjust so that the bend of clutch outer
cable becomes flatter.
2. HYDRAULIC APPLICATION TYPE
1) Check fluid level using a scale on outside of
reservoir tank. If the level is below ªMINº, add
clutch fluid to bring it up to ªMAXº.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or DOT4
brake fluid
CAUTION:
IAvoid mixing different brakes of brake fluid
to prevent degradation of the fluid.
IBe careful not to allow dirt or dust to get into
the reservoir tank.
IUse fresh DOT3 or DOT4 brake fluid when
refilling fluid.
S2M0351A
2) Make sure that brake fluid does not leak from
master cylinder, operating cylinder and piping.
3) Apply grease sufficiently to the release lever
pinion.
4) Check for proper clutch disengagement and
clutch pedal return ability.
2. On-car Service
A: ADJUSTMENT
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring from lever
(Models without hill holder only).
2) Adjust spherical nut so that the play is within the
specified value at the lever end (center of spheri-
cal nut).
Play:
3Ð4mm(0.12 Ð 0.16 in)
Full stroke:
24 Ð 26 mm (0.94 Ð 1.02 in)
CAUTION:
Take care not to twist the cable during adjust-
ment.
G2M0234
3) Upon completion of adjustment, securely lock
spherical nut with lock nut.
G2M0235
4) Install return spring on lever (Models without hill
holder only).
NOTE:
Hook the long hook side of the return spring with
the lever (Models without hill holder only).
6
2-10[W1A0]SERVICE PROCEDURE
1. General