2004 SUBARU FORESTER brake
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CL-31
CLUTCH SYSTEM
Clutch Fluid
8. Clutch Fluid
A: INSPECTION
1) Park the vehicle on a level surface.
2) Inspect the fluid level using scale on the outside
of the reservoir tank. If the level is below “MIN”, add
fluid to bring it up to “MAX”, and also inspect for
leakage.
B: REPLACEMENT
CAUTION:
The FMVSS No. 116, fresh DOT3 or DOT4
brake fluid must be used.
Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
splashed over surrounding parts.
Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
For convenience and safety, it is advisable to
have two men working.
1) Remove the air cleaner case and air chamber.
2) Either jack-up the vehicle and place a rigid rack
under it, or lift-up the vehicle.
3) Draw out the brake fluid from reservoir tank with
syringe.
4) Refill the reservoir tank with new recommended
brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake
fluid
5) Drain fluid in the same method as air bleeding.
6) Refill the brake fluid before reservoir tank be-
comes empty, and drain contaminated fluid again.
7) Repeat the above procedure until the contami-
nated fluid is completely drained.
(A) Reservoir tank
(B) MIN level
(C) MAX level
PM-00076
(A)
(B) (C)
Page 2858 of 2870
CL-32
CLUTCH SYSTEM
Clutch Fluid Air Bleeding
9. Clutch Fluid Air Bleeding
A: PROCEDURE
1. NON-TURBO MODEL
NOTE:
Bleed air from the oil line with help of co-worker.
1) Remove the air cleaner case and air intake duct.
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.
3) Slowly depress the clutch pedal and keep it de-
pressed. 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.
4) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.5) Tighten the air bleeder.
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
6) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
7) After bleeding air from the system, ensure that
clutch operates properly.
2. TURBO MODEL
NOTE:
Bleed air from the oil line with help of co-worker.
1) Remove the intercooler.
2) Fit one end of a vinyl tube into the air bleeder of
master cylinder and put the air bleeder of other end
into a brake fluid container. (RHD turbo model)
3) Slowly depress the clutch pedal and keep it de-
pressed. 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. (RHD turbo model)
4) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening to prevent brake fluid from being
splashed over surrounding parts.
(A) Clutch hose
(B) Air bleeder
(A) Operating cylinder
(B) Vinyl tube
CL-00063
(B)(A)
CL-00064
(B)
(A)
(A) Vinyl tube
CL-00065
T
(A)
CL-00066
Page 2859 of 2870
CL-33
CLUTCH SYSTEM
Clutch Fluid Air Bleeding
5) Tighten the air bleeder. (RHD turbo model)
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
6) Remove the operating cylinder.
NOTE:
Do not remove the clutch hose.
7) Fix the piston with clamp to avoid the piston from
jumping out.
8) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.9) Slowly depress the clutch pedal and keep it de-
pressed. 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.
NOTE:
Set the air breather screw part higher than tip of op-
erating cylinder when performing this procedure.
10) Repeat these steps until there are no more air
bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
11) Tighten the air bleeder.
Tightening torque:
T: 8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
12) Install the operating cylinder.
Tightening torque:
T: 37 N
⋅m (3.8 kgf-m, 27.5 ft-lb)
13) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
14) After bleeding air from the system, ensure that
clutch operates properly.
15) Install the intercooler.
CL-00067
T
CL-00068
CL-00069
(A) Operating cylinder
(B) Vinyl tube
CL-00070
(B) (A)
CL-00068
Page 2860 of 2870
CL-34
CLUTCH SYSTEM
Clutch Pedal
10.Clutch Pedal
A: REMOVAL
1. LHD MODEL
1) Remove the steering column.
2) Disconnect the connectors from stop light switch
and clutch switch.
3) Remove the snap pins which secure lever to
push rod and operating rod.
4) Remove the clevis pins which secure lever to
push rod and operating rod.
5) Remove the accelerator pedal.
6) Remove the air cleaner case and intake duct.
(Non-turbo model)
7) Remove the intercooler. (Turbo model)
8) Remove the PHV adjusting nut and lock nut.
(Model with hill holder)9) Remove the cable clamp, and disconnect the
PHV cable from PHV. (Model with hill holder)
CAUTION:
Carefully protect the boot and inner cable from
damage when disconnecting the PHV cable.
10) Remove the nut which secures clutch master
cylinder.
11) Remove the bolts and nuts which secure brake
and clutch pedals, and remove the pedal assembly.
(A) Operating rod
(B) Push rod
(C) Snap pin
(D) Clevis pin
(A) Adjusting nut
(B) Lock nut
(C) PHV
(D)
(B)(C)
(C) (D)(A)
CL-00090
CL-00091
(C)(B) (A)
(A) PHV cable
(B) Clamp
(B) (A)
CL-00092
CL-00093
Page 2863 of 2870
CL-37
CLUTCH SYSTEM
Clutch Pedal
5) Remove the following parts (B to H) from clutch
pedal bracket (A) as shown in the figure.
6) Remove the spacer, bushing and pedal pad from
clutch pedal.
D: ASSEMBLY
1) Attach the stopper, etc. to pedal bracket tempo-
rarily.
2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach the brake pedal return spring,
assist rods, spring, and bushing.
NOTE:
Clean up inside of bushings and apply grease be-
fore installing the spacer.
4) Install the hill holder cable to clutch pedal.
E: INSPECTION
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction
with a force of approx. 10 N (1 kgf, 2 lb) to ensure
pedal deflection is in specified range.
NOTE:
If excessive deflection is noted, replace the bush-
ings with new ones.
Deflection of clutch pedal:
Service limit
2.0 mm (0.079 in) or less
F: ADJUSTMENT
1. LHD MODEL
1) Measure the full stroke amount of clutch pedal.
NOTE:
Measure the length between seat cushion front
end and center portion of clutch pedal.
Slide the seat at seventh notch from first notch.
Specified clutch pedal full stroke: A
130 — 135 mm (5.12 — 5.31 in)
(A) Clutch pedal bracket
(B) Bushing C
(C) Clip
(D) O-ring
(E) Bushing S
(F) Spring S
(G) Rod S
(H) Bushing
(A) Spacer
(B) Bushing
(C) Bushing
(D) Pedal pad
(E) Clutch pedal
(F) Bushing C
( A )
( B )
( C )
( D )
( E )
( F )( G )
( H )
CL-00129
( A )
( B )
( B )
( C )
( D )
( E )
( F )
( F )
CL-00130
(A) Clutch pedal
(B) Brake pedal
(A) Clutch (Full stroke condition)
(B) Scale
(C) Seat
CL-00098
CL-00078(A)(B)(C)A
Page 2866 of 2870
CL-40
CLUTCH SYSTEM
Clutch Pedal
6) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
7) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt.
8) Turn the push rod further 270° counterclockwise
to lengthen (arrow direction as shown in the figure).
9) Move the clevis pin in lateral direction to ensure
it moves smoothly.
10) Tighten the push rod lock nut.
Tightening torque :
10 N
⋅m (1.0 kgf-m, 7.2 ft-lb)
11) Measure the full stroke amount of clutch pedal
again.
Specified clutch pedal full stroke: A
125 — 130 mm (4.92 — 5.12 in)
12) Install the clutch switch.
(A) Stopper bolt
(A) Clutch pedal
(B) Brake pedal
CL-00134
(A)
CL-00085
(A)
(B)
Page 2868 of 2870
CL-42
CLUTCH SYSTEM
General Diagnostic Table
12.General Diagnostic Table
A: INSPECTION
1. CLUTCH
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
Engine speed up when shifting.
High speed driving is impossible; espe-
cially rapid acceleration impossible and
vehicle speed does not increase in pro-
portion to an increase in engine speed.
Power falls, particularly when ascend-
ing a slope, and there is a smell of burn-
ing of the clutch facing.
Method of testing: Put the vehicle in
stationary condition 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) Clutch facing smeared by oil Replace.
(b) Worn clutch facing Replace.
(c) Deteriorated diaphragm spring Replace.
(d) Distorted pressure plate or flywheel Replace.
(e) Defective release bearing holder 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 this
sort is due to defective synchronization
mechanism, carry out the test as
described after.
Method of testing:
DRAG, INSPECTION, General Diagnos-
tic Table.>
It may be judged as insufficient disen-
gagement of clutch if any noise occurs
during this test.(a) Worn or rusty clutch disc hub spline Replace the clutch disc.
(b) Excessive deflection of clutch disc
facingReplace.
(c) Malfunction of crankshaft pilot bearing Replace.
(d) Cracked clutch disc facing Replace.
(e) Stuck clutch disc (smeared by oil or
water)Replace.
3. Clutch chatters.
Clutch chattering is an unpleasant vibra-
tion to the whole body when the vehicle is
just started with clutch partially engaged.(a) Adhesion of oil on the facing Replace the clutch disc.
(b) Weak or broken torsion spring Replace the clutch disc.
(c) Defective facing contact or excessive
disc wornReplace the clutch disc defection.
(d) Warped pressure plate or flywheel Replace.
(e) Loose disc rivets Replace the clutch disc.
(f) Loose engine mounting Retighten or replace the mounting.
(g) Improper adjustment of pitching stop-
perAdjustment.