ECU SUBARU FORESTER 2004 Service Repair Manual

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.

CL-21
CLUTCH SYSTEM
Release Bearing and Lever
B: INSTALLATION
1. NON-TURBO MODEL
1) Before assembly, lubricate the following points
with a coat of grease.
 Contact surface of lever and pivot
 Contact surface of lever and bearing
 Transmission main shaft spline (Use grease con-
taining molybdenum disulfide.)
 Contact surface of lever and operating cylinder
2) While pushing the fork to pivot and twisting it to
both sides, fit the retainer spring onto the constrict-
ed portion of pivot.
Apply grease (SUNLIGHT 2: Part No. 003602010)
to the contact point of release lever and operating
cylinder.
3) Confirm that the retainer spring is securely fitted
by observing it through the main case hole.
4) Install the release bearing and fasten it with two
clips.
5) Install the release lever dust cover.
6) Verify that the bearing moves smoothly with op-
erating release fork.
7) Install the transmission assembly.
mission Assembly.>
2. TURBO MODEL
1) Install the release bearing on transmission.
2) Insert the release fork into release bearing tab.
3) Apply grease to the specified points:
 Spline FX2200 (Part No. 000040901)
 Shaft SUNLIGHT 2 (Part No. 003602010)
(A) Release lever
(A) Release lever
(B) Release lever dust cover
CL-00026
(A)
CL-00023
(A)
(B)
(A) Release fork
(B) Release bearing
(A) Spline (FX2200)
(B) Shaft (SUNLIGHT 2)
CL-00028
(A)
(B)
CL-00029 (A)
(B)

CL-34
CLUTCH SYSTEM
Clutch Pedal
10.Clutch Pedal
A: REMOVAL
1. LHD MODEL
1) Remove the steering column. REMOVAL, Tilt 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. SP(H4SO)-4, REMOVAL, Accelerator Pedal.>
6) Remove the air cleaner case and intake duct.
(Non-turbo model) AL, Air Cleaner Case.> MOVAL, Air Intake Duct.>
7) Remove the intercooler. (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>
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