Subaru Legacy (2005 year). Manual - part 702

CL-27

CLUTCH SYSTEM

Operating Cylinder

2. 6MT MODEL

1) Install in the reverse order of removal.

NOTE:
Before installing the operating cylinder, apply
grease (SUNLIGHT 2: Part No. 003602010) 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: 41 N

⋅

m (4.2 kgf-m, 30.2 ft-lb)

NOTE:
• Be sure to install the clutch hose with the mark-
ing side facing upward.
• Be careful not to twist the clutch hose during in-
stallation.

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

C: INSPECTION

1) Check the operating cylinder for damage. If op-
erating cylinder is damaged, replace it.
2) Check for fluid leakage or damaged boot on the
operating cylinder. If any leakage or damage is
found, replace the operating cylinder. 

(A) Marking

(B) Clutch hose

(C) Operating cylinder

CL-00211

T2

T1

CL-00041

(A)

(B)

(C)

CL-28

CLUTCH SYSTEM

Master Cylinder

6. Master Cylinder

A: REMOVAL

1) Thoroughly drain brake fluid from reservoir tank.
2) Remove the snap pin and clevis pin, and then
separate the push rod of master cylinder from
clutch pedal.

3) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO 2.0)-7, REMOVAL, Air In-
take Chamber.>
4) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
5) Disconnect the clutch pipes from master cylin-
der.
6) Remove the master cylinder and reservoir tank
as a unit.

CAUTION:
Be careful not to spill the brake fluid. Since 
brake fluid spilt on the vehicle body harms 
paint surface, immediately wash away with wa-
ter and wipe it off if it gets on the body.

B: INSTALLATION

1) Install the master cylinder to vehicle, and con-
nect the clutch pipe to master cylinder.

NOTE:
Check that the pipe is routed properly.

Tightening torque:

T1: 15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

T2: 18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

2) Connect the push rod of master cylinder to
clutch pedal, and install the clevis pin and snap pin.

NOTE:
Apply grease to the clevis pin.

3) After bleeding air from the clutch system, ensure
that clutch operates properly.
<Ref. to CL-34, Clutch Fluid Air Bleeding.>
4) Install the air intake chamber. (Non-turbo model)
<Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air In-
take Chamber.>
5) Install the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, INSTALLATION, Intercooler.>

(A) Clevis pin

(B) Snap pin

(C) Push rod

(D) Lock nut

(A) Master cylinder ASSY

(B) Clutch pipe

CL-00042

(A)

(B)

(C)

(D)

CL-00152

(A)

(B)

(A) Clevis pin

(B) Snap pin

(C) Push rod

CL-00153

T1

T2

CL-00045

(A)

(B)

(C)

CL-29

CLUTCH SYSTEM

Master Cylinder

C: DISASSEMBLY

1. 5MT NON-TURBO MODEL

1) Remove the straight pin and reservoir tank.

2) Remove the oil seal.

3) Move the cylinder boot backward.

4) Remove the snap ring.

CAUTION:
Be careful to prevent the rod, washer, piston 
and return spring from flying out when remov-
ing snap ring.

2. 5MT TURBO MODEL AND 6MT MODEL

1) Remove the straight pin and reservoir tank.

2) Remove the oil seal.

3) Move the cylinder boot backward.

4) Remove the snap ring.

CAUTION:
Be careful to prevent the rod, washer, piston 
and return spring from flying out when remov-
ing snap ring.
5) Remove the clutch damper.

(A) Reservoir tank

(B) Straight pin

(A) Oil seal

(B) Master cylinder

(A) Cylinder boot

(B) Master cylinder

CL-00178

(A)

(B)

CL-00179

(A)

(B)

CL-00048

(A)

(B)

(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)

CL-30

CLUTCH SYSTEM

Master Cylinder

D: ASSEMBLY

1. 5MT NON-TURBO MODEL

1) Apply a coat of grease to the contact surfaces of
the push rod and piston before installation.

Grease:

SILICONE GREASE G40M (Part No. 
004404003)

2) Assemble in the reverse order of disassembly.

Tightening torque:

10 N

⋅

m (1.0 kgf-m, 7.4 ft-lb)

2. 5MT TURBO MODEL AND 6MT MODEL

1) Install the clutch damper.

Tightening torque:

46.6 N

⋅

m (4.75 kgf-m, 34.4 ft-lb)

2) Apply a coat of grease to the contact surfaces of
the push rod and piston before installation.

Grease:

SILICONE GREASE G40M (Part No. 
004404003)

3) Assemble in the reverse order of disassembly.

Tightening torque:

10 N

⋅

m (1.0 kgf-m, 7.4 ft-lb)

E: INSPECTION

If any damage, deformation, wear, swelling, rust or
other faults is found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, clutch
damper cylinder boot or hose, replace the faulty
part.
• 5MT Non-turbo model

• 5MT turbo model and 6MT model

CL-00156

CL-00054

(A) Master cylinder body

(B) Return spring

(C) Piston

(D) Stop ring

(E) Push rod ASSY

(F) Cylinder boot

(A) Master cylinder body

(B) Return spring

(C) Piston

(D) Stop ring

(E) Push rod ASSY

(F) Clutch damper

(G) Cylinder boot

CL-00157

(A)

(B)

(C)

(D)

(E)

(F)

CL-00056

(B)

(C)

(D)

(E)

(A)

(F)

(G)