boot SUBARU FORESTER 2004 Service Owner's Guide

CL-27
CLUTCH SYSTEM
Master Cylinder
C: DISASSEMBLY
1. EXCEPT RHD TURBO MODEL
1) Remove the straight pin and reservoir tank.
2) Remove the oil seal.
3) Move the cylinder boot backward.
4) Remove the stop ring.
CAUTION:
Be careful when removing the stop ring to pre-
vent the rod, washer, piston and return spring
from flying out.
2. RHD TURBO MODEL
1) Remove the hose.
2) Remove the reservoir tank and bracket.
3) Remove the straight pin and adapter.
4) Remove the oil seal.
(A) Reservoir tank
(B) Straight pin
(A) Oil seal
(B) Master cylinder
(A) Cylinder boot
(B) Master cylinder
CL-00046
(A)
(B)
CL-00047
(A)
(B)
CL-00048
(A)
(B)
(A) Reservoir tank
(B) Bracket
(A) Straight pin
(B) Adapter
CL-00049
CL-00050
(A)(B)
CL-00051 (A)(B)
CL-00052

CL-28
CLUTCH SYSTEM
Master Cylinder
5) Move the cylinder boot backward.
6) Remove the stop ring.
CAUTION:
Be careful when removing the stop ring to pre-
vent the rod, washer, piston and return spring
from flying out.
7) Remove the air bleeder.
D: ASSEMBLY
1. EXCEPT RHD TURBO MODEL
1) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
2) To assemble the master cylinder, reverse the
sequence of disassembly procedure.
Tightening torque:
10 N
⋅m (1.0 kgf-m, 7 ft-lb)
2. RHD TURBO MODEL
1) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
2) Assemble in the reverse order of disassemble.
E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, cylinder
boot and hose replace the faulty part.
(A) Cylinder boot
(B) Master cylinder
CL-00048
(A)
(B)
CL-00054
(A) Master cylinder body
(B) Return spring
(C) Piston
(D) Stop ring
(E) Rod ASSY
(F) Clutch damper
(G) Cylinder boot
CL-00055
CL-00056
(B)
(C)
(D)
(E) (A)
(F)
(G)

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

CL-35
CLUTCH SYSTEM
Clutch Pedal
2. RHD MODEL
1) Disconnect the ground cable from battery.
2) Loosen the screws and clips, and then remove
the lower cover.
3) Disconnect the clutch switch connector. (Model
with cruise control system)
4) Remove the snap pin connecting clutch pedal
and clutch master cylinder rod, and then pull the
clevis pin out.
5) Remove the clutch master cylinder mounting
nut.
6) Remove the PHV adjusting nut and the lock nut.
(Model with hill holder)
7) 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.
8) Remove the clutch pedal bracket.
B: INSTALLATION
1) Install the clutch pedal bracket.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
2) Install the clutch master cylinder mounting nut.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
3) Insert the new clevis pin to assist rod A, and then
install the snap pin.
NOTE:
Apply a coat of grease to the clevis pin.
4) Adjust the stroke amount of clutch pedal. to CL-37, ADJUSTMENT, Clutch Pedal.>
5) Adjust the hill holder (Model with hill holder).

6) Connect the clutch switch connector. (Model
with cruise control system)
7) Install the instrument panel lower cover.
(A) Master cylinder
(A) Adjusting nut
(B) Lock nut
(C) PHV
CL-00072
CL-00164
(A)
CL-00091
(C)(B) (A)
(A) PHV cable
(B) Clamp
(A) Clutch pedal bracket
(B) Clutch pedal
(B) (A)
CL-00092
( A )
( B )
CL-00126