SUBARU LEGACY 1997 Service Repair Manual

B2M1179C
4) Installation is in the reverse order of removal.
NOTE:
Before installing operating cylinder, apply grease (SUN-
LIGHT 2: P/N 003602010) to contact point of release lever
and operating cylinder.
Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
5) After bleeding air from operating cylinder, ensure that
clutch operates properly.

G2M0979
6. Master Cylinder and Reservoir Tank
A: REMOVAL
1) Remove snap pin
2, clevis pin
1and separate push
rod

3of master cylinder from clutch pedal.
B2M1260A
2) Remove clutch hose from master cylinder.
CAUTION:
Plug up hose connection to prevent clutch fluid from
spilling out.
B2M1261A
3) Remove master cylinder with reservoir tank.
16
2-10SERVICE PROCEDURE
5. Operating Cylinder - 6. Master Cylinder and Reservoir Tank

B2M1179C
4) Installation is in the reverse order of removal.
NOTE:
Before installing operating cylinder, apply grease (SUN-
LIGHT 2: P/N 003602010) to contact point of release lever
and operating cylinder.
Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
5) After bleeding air from operating cylinder, ensure that
clutch operates properly.

G2M0979
6. Master Cylinder and Reservoir Tank
A: REMOVAL
1) Remove snap pin
2, clevis pin
1and separate push
rod

3of master cylinder from clutch pedal.
B2M1260A
2) Remove clutch hose from master cylinder.
CAUTION:
Plug up hose connection to prevent clutch fluid from
spilling out.
B2M1261A
3) Remove master cylinder with reservoir tank.
16
2-10SERVICE PROCEDURE
5. Operating Cylinder - 6. Master Cylinder and Reservoir Tank

G2M0987
B: INSPECTION
If any damage, deformation, wear, swelling, rust or other
faults are found on the cylinder, piston, push rod, fluid
reservoir, seat and gasket, replace the faulty part.
B2M1261A
C: INSTALLATION
1) Install master cylinder to body.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
B2M1260A
2) Install clutch hose to master cylinder.
CAUTION:
Check that hose is routed properly.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
B4M1189B
3) Connect push rod
3of master cylinder to clutch pedal,
and install clevis pin

1and snap pin
2.
NOTE:
Apply grease to clevis pin.
4) After bleeding air from system, ensure that clutch oper-
ates properly.

17
2-10SERVICE PROCEDURE
6. Master Cylinder and Reservoir Tank

G2M0970
7. Clutch Damper
A: REMOVAL AND INSTALLATION
1) Remove clutch hoses from clutch damper.
CAUTION:
Cover hose joint to prevent clutch fluid from flowing
out.
2) Remove clutch damper with bracket.
G2M0991
3) Installation is in the reverse order of removal.
Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
4) After bleeding air from system, ensure that clutch oper-
ates properly.

8. Clutch Fluid
A: REPLACEMENT
CAUTION:
The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.
Cover bleeder with waste cloth, when loosening it,
to prevent clutch fluid from being splashed over sur-
rounding parts.
Avoid mixing different brands of clutch fluid to pre-
vent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
During bleeding operation, keep the clutch reserve tank
filled with clutch fluid to eliminate entry of air.
Clutch pedal operating must be very slow.
For convenience and safety, it is advisable to have two
man working.
The amount of clutch fluid required is approximately 70
m
(2.4 US fl oz, 2.5 Imp fl oz) for total clutch system.
1) Either jack-up vehicle and place a safety stand under it,
or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the clutch fluid from reserve tank with syringe.
4) Refill reservoir tank with recommended clutch fluid.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
5) Bleed air from oil line with the help of a co-worker.

18
2-10SERVICE PROCEDURE
7. Clutch Damper - 8. Clutch Fluid

G2M0970
7. Clutch Damper
A: REMOVAL AND INSTALLATION
1) Remove clutch hoses from clutch damper.
CAUTION:
Cover hose joint to prevent clutch fluid from flowing
out.
2) Remove clutch damper with bracket.
G2M0991
3) Installation is in the reverse order of removal.
Tightening torque:
T1: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
T2: 25±7 N⋅m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
4) After bleeding air from system, ensure that clutch oper-
ates properly.

8. Clutch Fluid
A: REPLACEMENT
CAUTION:
The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.
Cover bleeder with waste cloth, when loosening it,
to prevent clutch fluid from being splashed over sur-
rounding parts.
Avoid mixing different brands of clutch fluid to pre-
vent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:
During bleeding operation, keep the clutch reserve tank
filled with clutch fluid to eliminate entry of air.
Clutch pedal operating must be very slow.
For convenience and safety, it is advisable to have two
man working.
The amount of clutch fluid required is approximately 70
m
(2.4 US fl oz, 2.5 Imp fl oz) for total clutch system.
1) Either jack-up vehicle and place a safety stand under it,
or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the clutch fluid from reserve tank with syringe.
4) Refill reservoir tank with recommended clutch fluid.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
5) Bleed air from oil line with the help of a co-worker.

18
2-10SERVICE PROCEDURE
7. Clutch Damper - 8. Clutch Fluid

1. Clutch System
Condition Possible cause and testing Corrective action
1. Clutch slip-
pageIt is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms.
(a) Engine revs up when shifting.
(b) High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does not increase in
proportion to an increase in engine speed.
(c) Power falls, particularly when ascending a slope, and there is a smell of burning 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) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f ) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or 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 the
this sort is due to defective synchronization mechanism, carry out the test as described after.
Method of testing: Refer to DIAGNOSTIC DIAGRAM on page after.
It may be judged as insufficient disengagement of clutch if any noise occurs during this test.
(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc facing Correct or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f ) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or water) Replace.
3. Clutch chat-
ters.Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially
engaged.
(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive disc Replace clutch disc defection.
(e) Warped pressure plate or flywheel Correct or replace.
(f ) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace mounting.
(h) Improper adjustment of pitching stopper Adjustment.
19
2-10DIAGNOSTICS
1. Clutch System

Condition Possible cause and testing Corrective action
4. Noisy
clutchExamine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged.
(a) Broken, worn or unlubricated release bearing Replace release bearing.
(b) Insufficient lubrication of pilot bearing Apply grease.
(c) Loose clutch disc hub Replace clutch disc.
(d) Loose torsion spring retainer Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch
grabs.When starting the vehicle with the clutch partially engaged, the clutch engages suddenly and the vehicle jumps
instead of making a smooth start.
(a) Grease or oil on facing Replace clutch disc.
(b) Deteriorated cushioning spring Replace clutch disc.
(c) Worn or rusted spline of clutch disc or mainTake off rust, apply grease or replace clutch shaft disc or
mainshaft.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f ) Deteriorated diaphragm spring Replace.
20
2-10DIAGNOSTICS
1. Clutch System

1. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Test (1)
Disengage the clutch and shift quickly from neutral to reverse in idling condition.
Gear noise
Ye s
No
Sufficient disengagement of clutch
Test (2)
Shift to reverse after 0.5 to 1.0 sec of clutch disengagement.
Gear noise
Ye s
No
Defective transmission
or excessive clutch drag torque
[Cause]
1. Defective pilot bearing
2. Excessive disc deflection
3. Defective transmission
4. Defective clutch disc hub spline
Test (3)
Shift the gear N,R several times during disengaging clutch as test (2).
Gear noise
Ye s
No
Sticked clutch disc
[Cause]
1. Clutch disc smeared by oil
2. Clutch disc smeared by rust
3. Defective clutch disc hub spline
Clutch drags.
[Cause]
1. Cracked clutch disc facing
2. Damaged or worn clutch cover
3. Malfunction of clutch release system
4. Insufficient clutch release amount
5. Excessive clutch pedal play






21
2-10DIAGNOSTICS
1. Clutch System

22
2-10DIAGNOSTICS
1. Clutch System

1. Engine Mounting
G2M0258

1Front cushion rubber


2Front engine mounting bracketTightening torque: N⋅m (kg-m, ft-lb)
T1: 26±7 (2.7±0.7, 19.5±5.1)
T2: 41±10 (4.2±1.0, 30±7)
T3: 79±15 (8.0±1.5, 58±11)
2
2-11COMPONENT PARTS
1. Engine Mounting