SUBARU FORESTER 2004 Service Repair Manual

CL-5
CLUTCH SYSTEM
General Description
2. CLUTCH PIPE AND HOSE (NON-TURBO MODEL)
 LHD MODEL
(1) Operating cylinder (6) Clutch pipeTightening torque: N⋅m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSYT1: 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pinT2: 15 (1.5, 10.8)
(4) Bracket (9) Snap pinT3: 18 (1.8, 13.0)
(5) Clip (10) LeverT4: 37 (3.8, 27.5)
CL-00107
(8) (7)
(9)(10)
(6)
(5) (4)
T3
T2
T3
(1)
T4
T1
T3
(2)(3)

CL-6
CLUTCH SYSTEM
General Description
 RHD MODEL
(1) Operating cylinder (7) Master cylinder ASSYTightening torque: N⋅m (kgf-m, ft-lb)
(2) Washer (8) Clevis pinT1: 8 (0.8, 5.8)
(3) Clutch hose (9) Snap pinT2: 15 (1.5, 10.8)
(4) Bracket (10) PedalT3: 18 (1.8, 13.0)
(5) Clamp (11) ClipT4: 25 (2.5, 18.1)
(6) Clutch pipe (12) BracketT5: 37 (3.8, 27.5)
CL-00003
T3
T2
T2
T4(9) (7)
(4)
(11)
(6)
(11) (12)
(5)
(10)
(1)
T5
T1
T3
(2)(3)
(8)

CL-7
CLUTCH SYSTEM
General Description
3. CLUTCH PIPE AND HOSE (TURBO MODEL)
 LHD MODEL
(1) Operating cylinder (6) Clutch pipeTightening torque: N⋅m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSYT1: 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pinT2: 15 (1.5, 10.8)
(4) Bracket (9) Snap pinT3: 18 (1.8, 13.0)
(5) Clip (10) LeverT4: 37 (3.8, 27.5)
CL-00161
(1)(2)(8)
(7)(9)
(10)
(3)
(6)
(5) (4)
T4
T1
T3
T2
T3T3

CL-8
CLUTCH SYSTEM
General Description
 RHD MODEL
(1) Operating cylinder (7) Clevis pinTightening torque: N⋅m (kgf-m, ft-lb)
(2) Washer (8) Snap pinT1: 7.5 (0.76, 5.53)
(3) Clutch hose (9) PedalT2: 8 (0.8, 5.8)
(4) Bracket (10) ClipT3: 15 (1.5, 10.8)
(5) Clamp (11) Clutch pipeT4: 18 (1.8, 13.0)
(6) Master cylinder ASSY (12) BracketT5: 25 (2.5, 18.1)
T6: 37 (3.8, 27.5)
CL-00004
(1)(2) (3)
T6
T2
T4
(7)
(8) (6)
(4)
(12)(11)
(5)
(10)
(11)(10)
(12) (10)
(11)
T4
T3
T3T3
T3
T1
T3A
A
B
T5
T5
(9)
B

CL-9
CLUTCH SYSTEM
General Description
4. MASTER CYLINDER
 NON-TURBO MODEL
(1) Reservoir cap (7) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Reservoir tank (8) Return springT1: 10 (1.0, 7)
(3) Oil seal (9) PistonT2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Push rod
(5) Master cylinder (11) Piston stop ring
(6) Clutch damper (12) Cylinder boot
CL-00005
(1)
(2)
(3)
(4)
(5)
(7)
(6)
T2
T1
(8)
(9)(10) (11)
(12)

CL-10
CLUTCH SYSTEM
General Description
 LHD TURBO MODEL
(1) Reservoir cap (7) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Reservoir tank (8) Return springT1: 10 (1.0, 7)
(3) Oil seal (9) PistonT2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Push rod
(5) Master cylinder (11) Piston stop ring
(6) Clutch damper (12) Cylinder boot
CL-00109
(3)(1)
(4)
(5)
T1
(8)
(9)(11)(12)
(10)
(2)
(7)
(6)
T2

CL-11
CLUTCH SYSTEM
General Description
 RHD TURBO MODEL
(1) Reservoir cap (8) Oil sealTightening torque: N⋅m (kgf-m, ft-lb)
(2) Reservoir tank (9) Master cylinderT1: 8 (0.8, 5.8)
(3) Washer (10) Return springT2: 10 (1.0, 7)
(4) Straight pin (11) PistonT3: 18 (1.8, 13.0)
(5) Clip (12) Push rod
(6) Hose (13) Piston stop ring
(7) Reservoir tank bracket (14) Cylinder boot
)
CL-00162
(8) (1)
(2)
(9)
T2
(10)
(11)(13)
(12) (14)
T1
T3
T3
(7)
(5)
(3) (3)
(6)
(5)
(4)

CL-12
CLUTCH SYSTEM
General Description
5. CLUTCH PEDAL
 LHD MODEL
(1) Stopper (12) Clutch clevis pin (23) Pedal bracket
(2) Bushing (13) Assist rod A (24) Clutch master cylinder bracket
(3) Spring pin (14) Clip (25) Lever
(4) Snap pin (15) Assist spring (26) Adjusting bolt
(5) Brake pedal pad (16) Assist bushing (27) Clutch switch (Model with cruise
control system)
(6) Brake pedal (17) Assist rod B
(7) Clevis pin (18) Spring A
(8) Brake pedal spring (19) RodTightening torque: N
⋅m (kgf-m, ft-lb)
(9) Clutch pedal pad (20) Bushing BT1: 8 (0.8, 5.8)
(10) Clutch pedal (21) ClipT2: 18 (1.8, 13.0)
(11) Bushing C (22) Stop light switch
CL-00110
(7)
(7) (12)
T1
T1
T1
T2
T2
T2(25)
(11)
(11)(4)
(2) (3)
(24)
(22)
(26)
(21)
(20)
(1)
(1)(1) (2)
(2)
(6)
(9)
(10) (11) (12) (15) (16) (17) (19)
(18)
(14)
(13)(14)
(5) (2)(8)(4) (23)
(27)

CLUTCH SYSTEM
General Description
 RHD MODEL
(1) Stopper (10) Assist rod B (17) Bushing
(2) Clutch pedal pad (11) Spring A (18) Pedal bracket
(3) Clutch pedal (12) Rod S (19) Adjusting bolt
(4) Bushing (13) Bushing B
(5) Clutch clevis pin (14) ClipTightening torque: N
⋅m (kgf-m, ft-lb)
(6) Assist rod A (15) Clutch switch (Model with cruise control system)T1: 8 (0.8, 5.8)
(7) Clip T2: 18 (1.8, 13.0)
(8) Assist spring (16) Spacer T3: 30 (3.1, 22.4)
(9) Assist bushing
CL-00111
(5)
T2
T3
T1
(16)
(13)
(14) (15)
(18)
(4)
(6)
(8)
(9)
(10)
(7)
(17)(1)
(1)
(2)
(3)
(4)
(17)
(4) (12)
(11)
(19)
CL-13

CL-14
CLUTCH SYSTEM
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
 Be careful not to burn yourself, because each
part on the vehicle is hot after running.
 Use SUBARU genuine fluid, grease etc. or the
equivalent. Do not mix fluid, grease etc. with that of
another grade or from other manufacturers.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Apply grease onto sliding or revolution surfaces
before installation.
 Before installing O-rings or snap rings, apply suf-
ficient amount of fluid to avoid damage and defor-
mation.
 Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
 Keep fluid away from the vehicle body. If any flu-
id contacts the vehicle body, immediately flush the
area with water.