light SUBARU FORESTER 2004 Service Repair Manual

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)

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-25
CLUTCH SYSTEM
Operating Cylinder
B: INSTALLATION
1) Apply grease (SUNLIGHT 2: Part No.
003602010) to the contact point of the release lever
and operating cylinder.
2) Install in the reverse order of removal.
Before installing the operating cylinder, apply
grease (SUNLIGHT 2: Part No. 003602010) to con-
tact point of the release lever and operating cylin-
der.
Tightening torque:
T1: 18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
T2: 37 N
⋅m (3.8 kgf-m, 27.5 ft-lb)
 NON-TURBO model
 TURBO modelNOTE:
 Be sure to install the clutch hose with the mark
side facing upward.
 Be careful not to twist the clutch hose during in-
stallation.
3) After bleeding air from the operating cylinder,
ensure that clutch operates properly.

C: INSPECTION
1) Check the operating cylinder for damage. If op-
erating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on boot. If any leakage or damage is
found, replace the operating cylinder.
T2
CL-00039T2
T1
CL-00040
T2
T1
(A) Marking
(B) Clutch hose
(C) Operating cylinder
CL-00041
(A)
(B) (C)

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