Subaru Legacy (2005 year). Manual - part 701

CL-23

CLUTCH SYSTEM

Release Bearing and Lever

4. Release Bearing and Lever

A: REMOVAL

1. 5MT MODEL

1) Remove the transmission assembly from vehi-
cle.
<Ref. to 5MT-30, REMOVAL, Manual Transmis-
sion Assembly.>
2) Remove the two clips from release lever and re-
move the release bearing.

CAUTION:
Be careful not to deform the clips.
3) Remove the dust cover.

4) Remove the lever spring from the pivot with a
screwdriver by accessing it through the clutch
housing release lever hole. Then remove the re-
lease lever.

2. 6MT MODEL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 6MT-34, REMOVAL, Manual Trans-
mission Assembly.>
2) Remove the release lever from transmission.
3) Put the release bearing to engine side.

4) Remove the release bearing from clutch cover
using a flat tip screwdriver.

B: INSTALLATION

1. 5MT MODEL

1) Lubricate the following points with the specified
grease prior to installation.
• Contact surface of lever and pivot
• Contact surface of lever and bearing
• Transmission main shaft spline (Use grease con-
taining molybdenum disulphide.)
2) While pushing the release lever into pivot and
twisting it to both sides, fit the lever spring onto the
constricted portion of pivot.

NOTE:
• Apply grease (KOPR-KOTE: Part No.
003603001) to the contact point of release lever
and operating cylinder.
• Observing from the main case hole, check that
the lever spring is installed securely.

3) Install the release bearing and fasten it with two
clips.

(A) Release lever

(B) Dust cover

(A) Release lever

(B) Screwdriver

CL-00023

( A )

( B )

CL-00024

( B )

( A )

(A) Release bearing

(A) Release lever

CL-00025

( A )

CL-00026

( A )

CL-24

CLUTCH SYSTEM

Release Bearing and Lever

4) Install the dust cover.

5) Check the bearing for smooth movement by op-
erating the release lever.
6) Install the transmission assembly.
<Ref. to 5MT-32, INSTALLATION, Manual Trans-
mission Assembly.>

2. 6MT MODEL

1) Install the release bearing onto transmission.
2) Insert the release lever into release bearing tab.

3) Apply grease to the specified points.

Grease:

NICHIMOLY N-130

4) Insert the release shaft into release lever.

NOTE:
Make sure the cutout portion of the release shaft
contacts spring pin.

(A) Release lever

(B) Dust cover

(A) Release lever

(B) Release bearing

CL-00023

( A )

( B )

ME-00052

(A)

(B)

(A) Spline

(A) Release lever

(B) Release shaft

(C) Spring pin

CL-00341

(A)

CL-00030

( A )

( B )

( C )

CL-25

CLUTCH SYSTEM

Release Bearing and Lever

5) Tighten the plug.

Tightening torque:

44 N

⋅

m (4.5 kgf-m, 32.5 ft-lb)

6) Check the release bearing and release lever for
smooth movement by operating the release lever.
7) Install the transmission assembly. <Ref. to 6MT-
36, INSTALLATION, Manual Transmission Assem-
bly.>

C: INSPECTION

1. RELEASE BEARING

CAUTION:
Since this bearing is grease-sealed and non-lu-
brication type, do not wash with gasoline or any 
other solvent when servicing clutch.
1) Check the bearing for smooth movement by ap-
plying force to the bearing in radial direction.

Radial direction stroke:

1.6 mm (0.063 in)

2) Check the bearing for smooth rotation by apply-
ing force to the bearing in thrust direction.

3) Check for wear or damage on the bearing case
surface which contacts lever.

2. RELEASE LEVER

Check the pivot and the contact area with release
bearing case in the lever for wear.

(A) Bearing case

CL-00031

CL-00032

(A)

(A) Bearing case

(A) Release lever

(B) Pivot

(C) Release bearing

CL-00160

(A)

CL-00034

(A)

(B)

(C)

CL-26

CLUTCH SYSTEM

Operating Cylinder

5. Operating Cylinder

A: REMOVAL

1) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO 2.0)-7, REMOVAL, Air In-
take Chamber.>
2) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
3) Disconnect the clutch hose from operating cylin-
der.

CAUTION:
Cover the hose joint to prevent clutch fluid from 
flowing out.
• 5MT model

• 6MT model

4) Remove the operating cylinder from transmis-
sion.
• 5MT model

• 6MT model

B: INSTALLATION

1. 5MT MODEL

1) Install in the reverse order of removal.

NOTE:
Before installing the operating cylinder, apply
grease (KOPR-KOTE: Part No. 003603001) to the
contact point of 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)

2) After bleeding air from the operating cylinder,
ensure that clutch operates properly.
<Ref. to CL-34, Clutch Fluid Air Bleeding.>

(A) Clutch hose

(B) Operating cylinder

(A) Clutch hose

(B) Operating cylinder

CL-00252

(A)

(B)

CL-00209

(A)

(B)

(A) Operating cylinder

CL-00253

CL-00210

(A)

CL-00254

T1

T2

T2