Subaru Legacy (2005 year). Manual - part 699

CL-15

CLUTCH SYSTEM

General Description

D: PREPARATION TOOL

1. SPECIAL TOOL 

2. GENERAL TOOL

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

498497100

CRANKSHAFT 
STOPPER

Used for stopping rotation of flywheel when loos-
ening/tightening bolt, etc.

499747100

CLUTCH DISC 
GUIDE

Used for installing clutch disc to flywheel.

499057000

TORX PLUS

®

Used for removing flywheel (dual mass flywheel 
type).

TOOL NAME

REMARKS

Circuit tester

Used for measuring resistance, voltage and ampere.

Dial gauge

Used for measuring clutch disc run-out.

Depth gauge

Used for measuring wear of clutch disc.

ST-498497100

ST-499747100

ST-499057000

CL-16

CLUTCH SYSTEM

Clutch Disc and Cover

2. Clutch Disc and Cover

A: REMOVAL

1. 5MT EC, EK AND KA MODEL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 5MT-30, REMOVAL, Manual Trans-
mission Assembly.>
2) Insert the ST to flywheel.
ST

499747100

CLUTCH DISC GUIDE

3) Remove the clutch cover and clutch disc.

NOTE:
• Take care not to allow oil on the clutch disc fac-
ing.
• Do not disassemble the clutch cover or clutch
disc.
• Be sure to put alignment marks on the flywheel
and clutch cover before removing clutch cover.

2. 5MT KS, K4, TURBO MODEL AND 6MT 
MODEL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 5MT-30, REMOVAL, Manual Trans-
mission Assembly.> <Ref. to 6MT-34, REMOVAL,
Manual Transmission Assembly.>

2) Install the ST to flywheel.
ST

499747100

CLUTCH DISC GUIDE

3) Remove the clutch cover and clutch disc.

NOTE:
• Take care not to allow oil on the clutch disc fac-
ing.
• Do not disassemble the clutch cover or clutch
disc.

B: INSTALLATION

1. 5MT EC, EK AND KA MODEL

1) Insert the ST into clutch disc, and install on the
flywheel by inserting the ST end into pilot bearing.

NOTE:
When installing the clutch disc, be careful to its di-
rection.
ST

499747100

CLUTCH DISC GUIDE

2) Install the clutch cover on flywheel and tighten
bolts to the specified torque.

NOTE:
• When installing the clutch cover on the flywheel,
position the clutch cover so that there is a gap of
120

° or more between the paint marks “

” on the

flywheel and clutch cover. (the paint marks “

”

indicate the directions of residual unbalance.)
• Note the front and rear of the clutch disc when in-
stalling.

(A) Dual mass flywheel

CL-00112

( A )

ST

CL-00113

(A) Clutch cover

(A) Flywheel side

CL-00011

( A )

S T

CL-00282

(A)

ST

(A)

CL-17

CLUTCH SYSTEM

Clutch Disc and Cover

• Tighten the clutch cover installing bolts gradual-
ly. Each bolt should be tightened to the specified
torque in a crisscross order.

Tightening torque:

16 N

⋅

m (1.6 kgf-m, 11.8 ft-lb)

3) Remove the ST.
ST

499747100

CLUTCH DISC GUIDE

4) Install the transmission assembly. <Ref. to 5MT-
32, INSTALLATION, Manual Transmission Assem-
bly.>

2. 5MT KS, K4, TURBO MODEL AND 6MT 
MODEL

1) Insert the ST into clutch disc, and install on the
flywheel by inserting the ST end into pilot bearing.

NOTE:
When installing the clutch disc, be careful to its di-
rection.
ST

499747100

CLUTCH DISC GUIDE

2) Install the clutch cover on flywheel and tighten
the bolts to the specified torque.

NOTE:
• When installing the clutch cover on the flywheel,
position the clutch cover so that there is a gap of
120

° or more between the paint marks “

” on the

flywheel and clutch cover. (the paint marks “

”

indicate the directions of residual unbalance.)
• Note the front and rear of the clutch disc when in-
stalling.

• Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross order.

Tightening torque:

16 N

⋅

m (1.6 kgf-m, 11.8 ft-lb)

3) Remove the ST.
ST

499747100

CLUTCH DISC GUIDE

4) Install the transmission assembly. <Ref. to 5MT-
32, INSTALLATION, Manual Transmission Assem-
bly.> <Ref. to 6MT-36, INSTALLATION, Manual
Transmission Assembly.>

C: INSPECTION

1. CLUTCH DISC

1) Wear of facing:
Measure the depth from the surface of facing to riv-
et head. Replace if the facings are worn locally or
worn down to less than the specified value.

Depth of rivet head:

Limit of sinking

0.3 mm (0.012 in)

NOTE:
Do not wash the clutch disc with any cleaning fluid.

(A) Flywheel side

CL-00115

(1)

(2)

(3)

(4)

(5)

(6)

CL-00208

(A)

ST

(A) “0” mark

CL-00013

( A )

S T

( 2 )

( 5 )

( 3 )

( 1 )

( 6 )

( 4 )

CL-18

CLUTCH SYSTEM

Clutch Disc and Cover

• 5MT EC, EK and KA model

• 5MT KS, K4 model and 6MT model

• 5MT turbo model

2) Hardened facing
Replace the clutch disc.

3) Oil leakage on facing
Replace the clutch disc, and inspect the transmis-
sion front oil seal, transmission case mating sur-
face, engine rear oil seal and other points for oil
leakage.
• 5MT EC, EK and KA model

• 5MT KS, K4 model and 6MT model

• 5MT turbo model

CL-00116

CL-00014

CL-00387

(A) Clutch facing

(A) Clutch facing

(A) Clutch facing

( A )

CL-00117

CL-00015

(A)

CL-00388

(A)