1999 SUBARU LEGACY Service Repair Manual

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
G2M0253
4) Install clutch cover on flywheel and tighten bolts
to the specified torque.
NOTE:
IWhen installing the clutch cover on the flywheel,
position the clutch cover so that there is a gap of
120É or more between ª0º marks on the flywheel
and clutch cover. (ª0º marks indicate the directions
of residual unbalance.)
INote the front and rear of the clutch disc when
installing.
ITighten 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
B2M1011A
14
2-10[W4C0]SERVICE PROCEDURE
4. Clutch Disc and Cover

5. Operating Cylinder
A: REMOVAL AND INSTALLATION
1) Remove air chamber.

B2M1265
2) Remove clutch hose from operating cylinder.
CAUTION:
Cover hose joint to prevent brake fluid from
flowing out.
B2M1179B
3) Remove operating cylinder from transmission.
B2M1263
4) Installation is in the reverse order of removal.
NOTE:
Before installing operating cylinder, apply grease
(SUNLIGHT 2: P/N 003602010) to contact point of
release lever and operating cylinder.
Tightening torque:
T1: 18
±3 N´m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 37
±3 N´m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B2M1179C
5) After bleeding air from operating cylinder,
ensure that clutch operates properly.

15
[W5A0]2-10SERVICE PROCEDURE
5. Operating Cylinder

6. Master Cylinder and
Reservoir Tank
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir
tank.
2) Remove snap pin, clevis pin and separate push
rod of master cylinder from clutch pedal.
B4M1189A
3) Remove clutch pipe from master cylinder.
4) Remove master cylinder with reservoir tank.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the paint surface; wipe it off quickly if spilt.
S2M0352A
B: DISASSEMBLY
1) Remove straight pin and reservoir tank.
S2M0356A
2) Remove oil seal.
S2M0357A
3) Move the cylinder boot backward.
S2M0358A
4) Remove snap ring.
CAUTION:
Be careful when removing the snap ring to pre-
vent the rod, washer, piston and return spring
from flying out.
5) Remove damper cylinder from master cylinder
body.
S2M0359A
16
2-10[W6A0]SERVICE PROCEDURE
6. Master Cylinder and Reservoir Tank

C: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring and gasket,
replace the faulty part.
S2M0353A
(A) Master cylinder body
(B) Return spring
(C) Piston
(D) Snap ring
(E) Rod assy
(F) Washer
(G) Damper cylinder
D: ASSEMBLY
CAUTION:
Apply a coat of grease to the contacting sur-
faces of the push rod and piston before instal-
lation.
1) To assemble the master cylinder reverse the
sequence of disassembly procedure.
2) Install damper cylinder washer. Install damper
cylinder and tighten to the specified torque.
Tightening torque:
T: 46.6
±7.4 N´m (4.75±0.75 kg-m, 34.4±5.4
ft-lb)
E: INSTALLATION
1) Install master cylinder to body, and install clutch
pipe to master cylinder.
CAUTION:
Check that pipe is routed properly.
Tightening torque:
T: 1 8
±3 N´m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
S2M0352B
2) Connect push rod of master cylinder to clutch
pedal, and install clevis pin and snap pin.
NOTE:
Apply grease to clevis pin.
B4M1189C
(A) Clevis pin
(B) Snap pin
(C) Push rod
3) After bleeding air from system, ensure that
clutch operates properly.

17
[W6E0]2-10SERVICE PROCEDURE
6. Master Cylinder and Reservoir Tank

7. Brake Fluid
A: REPLACEMENT
CAUTION:
IThe FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
ICover bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
IAvoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
IBe careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
IDuring bleeding operation, keep the clutch
reserve tank filled with brake fluid to eliminate entry
of air.
IClutch pedal operating must be very slow.
IFor convenience and safety, it is advisable to
have two man working.IThe amount of brake fluid required is approxi-
mately 70 m(2.4 US fl oz, 2.5 Imp fl oz) for total
clutch system.
1) Either jack-up vehicle and place a safety stand
under it, or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from reserve tank with
syringe.
4) Refill reservoir tank with recommended brake
fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake
fluid
5) Bleed air from oil line with the help of a co-
worker.

18
2-10[W7A0]SERVICE PROCEDURE
7. Brake Fluid

1. Clutch System
Symptom Possible cause Corrective
1. Clutch slippage.
It is hard to perceive clutch slippage in the early stage,
but pay attention to the following symptoms
IEngine revs up when shifting.
IHigh speed driving is impossible; especially rapid
acceleration impossible and vehicle speed does not
increase in proportion to an increase in engine speed.
IPower falls, particularly when ascending a slope,
and there is a smell of burning of the clutch facing.
IMethod of testing: Put the vehicle in stationary con-
dition with parking brake fully applied. Disengage the
clutch and shift the transmission gear into the first.
Gradually allow the clutch to engage while gradually
increasing the engine speed. The clutch function is
satisfactory if the engine stalls. However, the clutch is
slipping if the vehicle does not start off and the engine
does not stall.(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch drags.
As a symptom of this trouble, a harsh scratching noise
develops and control becomes quite difficult when
shifting gears. The symptom becomes more apparent
when shifting into the first gear. However, because
much trouble of the this sort is due to defective syn-
chronization mechanism, carry out the test as
described after.

It may be judged as insufficient disengagement of
clutch if any noise occurs during this test.(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc
facingCorrect or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or
water)Replace.
3. Clutch chatters.
Clutch chattering is an unpleasant vibration to the
whole body when the vehicle is just started with clutch
partially engaged.(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive
discReplace clutch disc defec-
tion.
(e) Warped pressure plate or flywheel Correct or replace.
(f) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace
mounting.
(h) Improper adjustment of pitching stop-
perAdjustment.
4. Noisy clutch
Examine whether the noise is generated when the
clutch is disengaged, engaged, or partially engaged.(a) Broken, worn or unlubricated release
bearingReplace release bearing.
(b) Insufficient lubrication of pilot bearing Apply grease.
(c) Loose clutch disc hub Replace clutch disc.
(d) Loose torsion spring retainer Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch grabs.
When starting the vehicle with the clutch partially
engaged, the clutch engages suddenly and the vehicle
jumps instead of making a smooth start.(a) Grease or oil on facing Replace clutch disc.
(b) Deteriorated cushioning spring Replace clutch disc.
(c) Worn or rusted spline of clutch disc or
mainTake off rust, apply
grease or replace clutch
shaft disc or mainshaft.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace
mounting.
(f) Deteriorated diaphragm spring Replace.
19
[K100]2-10DIAGNOSTICS
1. Clutch System

A: DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
B2M1012A
20
2-10[K1A0]DIAGNOSTICS
1. Clutch System

MEMO:
21
2-10DIAGNOSTICS