1999 SUBARU LEGACY Service Repair Manual

5) Depress clutch pedal to assure there is no
abnormality in the clutch system.
G2M0236
2. HYDRAULIC APPLICATION TYPE
NOTE:
Bleed air from oil line with the help of a co-worker.
1) Remove air chamber.
2) Fit one end of a vinyl tube into the air bleeder
of operating cylinder and put the other end into a
brake fluid container.
B2M1179F
3) Slowly depress the clutch pedal and keep it
depressed. Then open the air bleeder to discharge
air together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.
B2M1178A
4) Repeat these steps until there are no more air
bubbles in the vinyl tube.CAUTION:
Cover bleeder with waste cloth when loosening
it, to prevent brake fluid from being splashed
over surrounding parts.
5) Tighten air bleeder.
Tightening torque:
T: 1 8
±3 N´m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
B2M1179A
6) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
7) After bleeding air from system, ensure that
clutch operates properly.
7
[W2A2]2-10SERVICE PROCEDURE
2. On-car Service

3. Release Bearing and Lever
A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove transmission assembly from vehicle
body.

2) Remove release lever return spring (Models
without hill holder only).
3) Remove the two clips from clutch release lever
and remove release bearing.
CAUTION:
Be careful not to deform clips.
4) Remove release lever seal.
B2M0633D
(A) Release lever return spring
(B) Clip
(C) Release lever
(D) Release lever seal
(E) Retainer spring
(F) Clutch release lever
5) Remove release lever retainer spring from
release lever pivot with a screwdriver by accessing
it through clutch housing release lever hole. Then
remove release lever.
B2M0174A
2. HYDRAULIC APPLICATION TYPE
1) Remove transmission assembly from vehicle
body.

2) Remove operating cylinder.

3) Remove the two clips from clutch release lever
and remove release bearing.
CAUTION:
Be careful not to deform clips.
4) Remove release lever seal.
B2M1257G
(A) Operating cylinder
(B) Clip
(C) Clutch release lever
(D) Release bearing
(E) Release lever seal
8
2-10[W3A1]SERVICE PROCEDURE
3. Release Bearing and Lever

5) Remove release lever retainer spring from
release lever pivot with a screwdriver by accessing
it through clutch housing release lever hole. Then
remove release lever.
B2M1258A
B: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a
nonlubrication type, do not wash with gasoline
or any solvent 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)
B2M0173A
2) Check the bearing for smooth rotation by apply-
ing pressure in the thrust direction.
G2M0240
3) Check wear and damage of bearing case sur-
face contacting with lever.
2. RELEASE LEVER
1) Check lever pivot portion and the point of con-
tact with release bearing case for wear.
G2M0241
C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the fol-
lowing points with a light coat of grease.
IInner groove of release bearing
IContact surface of lever and pivot
IContact surface of lever and bearing
ITransmission main shaft spline (Use grease
containing molybdenum disulphide.)
9
[W3C0]2-10SERVICE PROCEDURE
3. Release Bearing and Lever

1. MECHANICAL APPLICATION TYPE
1) While pushing release lever to pivot and twist-
ing it to both sides, fit retainer spring onto the con-
stricted portion of pivot.
NOTE:
Confirm that retainer spring is securely fitted by
observing it through the main case hole.
2) Install release bearing and fasten it with two
clips.
3) Install release lever seal.
B2M0633E
(A) Release lever return spring
(B) Clip
(C) Release lever
(D) Release lever seal
(E) Retainer spring
(F) Release lever bearing
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 adjust-
ment.
G2M0235
5) Install release lever return spring (Models with-
out hill holder only).
NOTE:
Hook up the return spring to right side hole of the
release lever.
10
2-10[W3C1]SERVICE PROCEDURE
3. Release Bearing and Lever

2. HYDRAULIC APPLICATION TYPE
1) While pushing release lever to pivot and twist-
ing it to both sides, fit retainer spring onto the con-
stricted portion of pivot.
NOTE:
IApply grease (SUNLIGHT 2: P/N 003602010) to
contact point of release lever and operating cylin-
der.
IConfirm that retainer spring is securely fitted by
observing it through the main case hole.
2) Install release bearing and fasten it with two
clips.
3) Install release lever seal.
4) Install operating cylinder.
Tightening torque:
T: 3 7
±3 N´m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B2M1257F
(A) Release lever
(B) Retainer spring
(C) Release bearing
(D) Clip
(E) Release lever seal
(F) Operating cylinder
5) After remounting engine and transmission on
body.

6) Bleed air from oil line with the help of a co-
worker.

4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100C RANKSHAFT STOPPER
G2M0242
2) Remove clutch cover and clutch disc.
CAUTION:
ITake care not to allow oil on the clutch disc
facing.
IDo not disassemble either clutch cover or
clutch disc.
3) Remove flywheel.
G2M0243
11
[W4A0]2-10SERVICE PROCEDURE
4. Clutch Disc and Cover

2. HYDRAULIC APPLICATION TYPE
1) While pushing release lever to pivot and twist-
ing it to both sides, fit retainer spring onto the con-
stricted portion of pivot.
NOTE:
IApply grease (SUNLIGHT 2: P/N 003602010) to
contact point of release lever and operating cylin-
der.
IConfirm that retainer spring is securely fitted by
observing it through the main case hole.
2) Install release bearing and fasten it with two
clips.
3) Install release lever seal.
4) Install operating cylinder.
Tightening torque:
T: 3 7
±3 N´m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B2M1257F
(A) Release lever
(B) Retainer spring
(C) Release bearing
(D) Clip
(E) Release lever seal
(F) Operating cylinder
5) After remounting engine and transmission on
body.

6) Bleed air from oil line with the help of a co-
worker.

4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100C RANKSHAFT STOPPER
G2M0242
2) Remove clutch cover and clutch disc.
CAUTION:
ITake care not to allow oil on the clutch disc
facing.
IDo not disassemble either clutch cover or
clutch disc.
3) Remove flywheel.
G2M0243
11
[W4A0]2-10SERVICE PROCEDURE
4. Clutch Disc and Cover

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 Ð 1.9 mm (0.051 Ð 0.075 in)
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning
fluid.
B2M0328
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.
B2M0329A
4) Deflection on facing
If deflection exceeds the specified value at the
outer circumference of facing, repair or replace.
Limit for deflection:
1.0 mm (0.039 in) at R = 107 mm (4.21 in)
B2M0330A
5) Worn spline, loose rivets and torsion spring fail-
ure
Replace defective parts.
B2M0333A
2. CLUTCH COVER
NOTE:
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 cen-
ter of diaphragm spring.
G2M0248
12
2-10[W4B1]SERVICE PROCEDURE
4. Clutch Disc and Cover

3) Damaged or worn disc contact surface of pres-
sure plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.
G2M0249
3. FLYWHEEL
CAUTION:
Since this bearing is grease sealed and is of a
nonlubrication type, do not wash with gasoline
or any solvent.
1) Damage of facing and ring gear
If defective, replace flywheel.
G2M0250
2) Smoothness of rotation
Rotate ball bearing applying pressure in thrust
direction.3) 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 surface is flush with clutch disc contact sur-
face of flywheel. Do not press inner race.
ST 899754112 SNAP RING PRESS
H2M1563A
C: INSTALLATION
1) Install flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER
B2M0332A
2) Tighten the flywheel attaching bolts to the
specified torque.
NOTE:
Tighten flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in
a crisscross fashion.
Tightening torque:
72
±3 N´m (7.3±0.3 kg-m, 52.8±2.2 ft-lb)
B2M0331B
13
[W4C0]2-10SERVICE PROCEDURE
4. Clutch Disc and Cover