Subaru Legacy (2005 year). Manual - part 704

CL-35

CLUTCH SYSTEM

Clutch Fluid Air Bleeding

5) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and the other end into a brake
fluid container.
6) Slowly depress the clutch pedal and keep it de-
pressed. Open the air bleeder to discharge air to-
gether with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.

NOTE:
Bring the air breather screw part higher than the tip
of operating cylinder when performing this proce-
dure.

7) Repeat these steps until there are no more air
bubbles in the vinyl tube.

CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being 
splashed over surrounding parts.
8) Tighten the air bleeder.

Tightening torque:

8 N

⋅

m (0.8 kgf-m, 5.8 ft-lb)

9) Install the operating cylinder.

Tightening torque:

41 N

⋅

m (4.2 kgf-m, 30.2 ft-lb)

10) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
11) After bleeding air from the system, ensure that
clutch operates properly.

12) Install the air cleaner case. <Ref. to IN(H6DO)-
5, REMOVAL, Air Cleaner Case.>

(A) Operating cylinder

(B) Vinyl tube

CL-00070

(B)

(A)

CL-00068

CL-36

CLUTCH SYSTEM

Clutch Pedal

10.Clutch Pedal

A: REMOVAL

1. LHD MODEL

1) Disconnect the ground cable from battery.
2) Remove the steering column. <Ref. to PS-24,
REMOVAL, Tilt Steering Column.>
3) Disconnect the connectors from the stop light
switch and clutch switch.
4) Remove the snap pins from the clevis pins which
secure lever to push rod and operating rod.
5) Remove the clevis pins which secure lever to
push rod and operating rod.

6) Remove the nut which secures clutch master
cylinder.

7) Remove the bolts which secure brake pedal and
clutch pedal, and remove the pedal assembly.

2. RHD MODEL

1) Disconnect the ground cable from battery.
2) Remove the instrument panel lower cover.
3) Remove the clutch pedal catcher from bracket
(clutch pedal catcher).

4) Remove the clutch switch connector from clutch
pedal.
5) Remove the snap pin and clevis pin which join
the push rod and clutch pedal.
6) Remove the master cylinder mounting nuts.

7) Remove the clutch pedal and bracket as a unit.

(A) Operating rod

(B) Push rod

(C) Snap pin

(D) Clevis pin

(D)

(B)

(C)

(C)

(D)

(A)

CL-00292

CL-00093

(A) Bracket (Clutch pedal catcher)

(B) Clutch pedal catcher

(C) Clutch pedal

(D) Steering support beam

(A) Master cylinder

(A) Clutch pedal bracket

(B) Clutch pedal

(A)

(B)

(C)

CL-00274

(D)

CL-00216

(A)

CL-00126

(A)

(B)

CL-37

CLUTCH SYSTEM

Clutch Pedal

B: INSTALLATION

1) Install in the reverse order of removal.

Tightening torque:

T: 18 N

⋅

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

• Clutch pedal catcher

CAUTION:
Always use a new clevis pin.
2) Adjust the clutch pedal after installation. <Ref. to
CL-39, ADJUSTMENT, Clutch Pedal.>

C: DISASSEMBLY

1. LHD MODEL

1) Remove the clutch switch.
2) Remove the clips, assist spring, rod and bush-
ing.

3) Remove the spring pin and remove lever.

4) Remove the clutch pedal and bushings.

5) Remove the stopper, clip and rod S, and then re-
move the spring and bushing S.

6) Remove the stopper from clutch pedal.
7) Remove the clutch pedal pad.

(A) Bracket (Clutch pedal catcher)

(B) Clutch pedal catcher

(C) Clutch pedal

(D) Steering support beam

(A) Clip

(B) Assist spring

(C) Assist rod

(D) Bushing

(E) Clevis pin

(A)

(B)

(C)

CL-00275

T

(D)

CL-00094

(A)

(B)

(C)

(C)

(D)

(D)

(D)

(E)

(E)

(A) Pin

(B) Lever

(A) Clutch pedal

(B) Bushing

(A) Clip (EC model and 2.5 L model)

(B) Bushing S (EC model and 2.5 L model)

(C) Spring S (EC model and 2.5 L model)

(D) Rod S (EC model and 2.5 L model)

(E) Stopper

CL-00095

(A)

(B)

CL-00096

(A)

(B)

(B)

CL-00097

(A)

(B)

(C)

(D)

(E)

CL-38

CLUTCH SYSTEM

Clutch Pedal

2. RHD MODEL

1) Remove the clutch switch.
2) Remove the clip, and then pull out the clevis pin.

3) Remove the assist rod, spring and bushing.
4) Remove the clutch pedal from clutch pedal
bracket.

5) Remove the following parts (B — G) from clutch
pedal bracket (A) as shown in the figure.

6) Remove the spacer, bushing and pedal pad from
clutch pedal.

D: ASSEMBLY

1. LHD MODEL

1) Attach the clutch switch, etc. to pedal bracket
temporarily.
2) Clean the inside of bores of clutch pedal and
brake pedal, apply a thin coat of grease, and then
set bushings into bores.
3) Align the bores of pedal bracket, clutch pedal
and brake pedal, and then attach the brake pedal
return spring, assist rods, spring and bushing.

NOTE:
Clean up the inside of bushings and apply a thin
coat of grease before installing spacer.

2. RHD MODEL

1) Clean the sliding surfaces of clutch pedal and
bushing, and apply a thin coat of grease on them.
2) Install the pad, stopper, bushing C, spacer and
bushing to clutch pedal.
3) Install the rod S, spring S, bushing S, clip, bush-
ing, clutch switch and bushing C to clutch pedal
bracket.

(A) Clevis pin

(A) Clutch pedal bracket

(B) Clutch pedal

(A) Clutch pedal bracket

(B) Bushing C

(C) Clip (2.0 L model and 2.5 L model)

(D) Bushing S (2.0 L model and 2.5 L model)

(E) Spring S (2.0 L model and 2.5 L model)

(F) Rod S (2.0 L model and 2.5 L model)

(G) Stopper

CL-00127

(A)

CL-00128

(A)

(B)

CL-00184

(A)

(B)

(C)

(D)

(E)

(F)

(G)

(A) Spacer

(B) Bushing

(C) Stopper

(D) Pedal pad

(E) Clutch pedal

(F) Bushing C

CL-00130

(A)

(B)

(B)

(C)

(D)

(E)

(F)

(F)