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Subaru Legacy (2005 year). Manual - part 705

CL-39

CLUTCH SYSTEM

Clutch Pedal

4) Install the pedal assembly, stopper, adjusting
rod, bushing and spring to clutch pedal bracket.

Tightening torque:

T: 30 N

⋅

m (3.1 kgf-m, 22.4 ft-lb)

5) Install the assist rod, bushing and assist spring
to clutch pedal and pedal bracket.

E: INSPECTION

1. CLUTCH PEDAL

Move the clutch pedal pads in the lateral direction
with a force of approx. 10 N (1 kgf, 2 lbf) to ensure
the pedal deflection is in specified range.
If excessive deflection is noted, replace the bush-
ing with new one.

Deflection of clutch pedal:

Service limit

5.0 mm (0.197 in) or less

• LHD model

• RHD model

F: ADJUSTMENT

1) Measure the amount of clutch pedal full stroke.

NOTE:
• Measure the length between the seat cushion
front end and center point of clutch pedal.
• Slide the seat at seventh notch from the first
notch.

Specified clutch pedal full stroke A:

Non-turbo model

130 — 135 mm (5.12 — 5.31 in)

Turbo model

135 — 140 mm (5.31 — 5.51 in)

2) If the full stroke is out of specification, loosen the
clutch stopper nut and adjust it.

Tightening torque:

8 N

⋅

m (0.8 kgf-m, 5.8 ft-lb)

(A) Clutch pedal bracket

(B) Clutch pedal

(A) Clutch pedal

(B) Brake pedal

(A)

(B)

CL-00276

CL-00098

(A)

(B)

(A) Clutch pedal

(B) Brake pedal

(A) Clutch pedal (at full stroke condition)

(B) Scale

CL-00077

(A)

(B)

CL-00078

(A)

(B)

(C)

CL-40

CLUTCH SYSTEM

Clutch Pedal

3) Loosen the push rod lock nut.

4) Turn the push rod to adjust.

(1) Ensure that the clutch pedal contacts clutch
switch side, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.

5) Turn the push rod counterclockwise to shorten
until clearance is made at clutch switch side.

6) Turn the push rod clockwise to lengthen until the
clutch pedal contacts to clutch switch.
7) Turn the push rod further 270

° counterclockwise

to shorten (the arrow direction shown in the figure).
• LHD model

• RHD model

8) Move the clevis pin right and left to ensure it
moves smoothly.

(A) Clevis pin

(B) Snap pin

(D) Push rod lock nut

(A) Clevis hole

(B) Push rod lock nut

(D) Lengthening direction

(E) Push rod

(F) U shaped bracket

CL-00042

(A)

(B)

(C)

(D)

CL-00080

(B)

(A)

(C)

(D)

(E)

(F)

(A) Clutch switch

(B) Stopper

(A) Accelerator pedal

(B) Clevis

(A) Clutch pedal

(B) Brake pedal

(A)

(B)

(C)

CL-00132

CL-00101

(B)

(A)

CL-00085

(A)

(B)

CL-41

CLUTCH SYSTEM

Clutch Pedal

9) Tighten the push rod lock nut.

Tightening torque:

10 N

⋅

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

10) Depress and release the clutch pedal two or
three times to ensure that clutch pedal and release
lever operate smoothly. If the clutch pedal and re-
lease lever do not operate smoothly, bleed air from
the clutch system. <Ref. to CL-34, Clutch Fluid Air
Bleeding.>
11) Measure the clutch pedal full stroke length
again to ensure that it is within specifications. If it is
not within the specified range, repeat the adjust-
ment procedure from the beginning.

Specified clutch pedal full stroke:

Non-turbo model

130 — 135 mm (5.12 — 5.31 in)

Turbo model

135 — 140 mm (5.31 — 5.51 in)

12) Move the clevis pin to the left, then to the right.
The clevis pin should move without resistance
while it is rattling. If resistance is felt, repeat the ad-
justment procedure again from the beginning.
13) Push the release lever until operating cylinder
push rod retracts. Ensure that the clutch fluid level
in reservoir tank increases. If the clutch fluid level
increases, clutch is adjusted correctly. If the fluid
level does not increase or push rod does not re-
tract, replace the master cylinder with new one.
<Ref. to CL-28, Master Cylinder.>
• 2.0 L Non-turbo model and Turbo model

• 3.0 L model

14) Push the release lever until operating cylinder
push rod retracts. Check that the clutch fluid level in
reservoir tank increases.
• 2.0 L Non-turbo model and Turbo model

• 3.0 L model

15) If the clutch fluid level increases, clutch play is
adjusted correctly.

(1) Push rod

(2) Release lever

(3) Operating cylinder

CL-00227

(1)

(2)

(3)

(1) Push rod

(2) Release lever

(3) Operating cylinder

(1) Push rod

(2) Release lever

(3) Operating cylinder

(1) Push rod

(2) Release lever

(3) Operating cylinder

CL-00402

(2)

(3)

(1)

CL-00227

(1)

(2)

(3)

CL-00402

(2)

(3)

(1)

CL-42

CLUTCH SYSTEM

Clutch Pedal

16) If the clutch fluid level does not increase or
push rod does not retract, clutch pedal must be re-
adjusted.
17) Inspect the fluid level using the scale on the
outside of reservoir tank. If the level is below “MIN”,
add clutch fluid to bring it up to “MAX”.

Recommended clutch fluid:

FMVSS No. 116, fresh DOT3 or 4 brake fluid

(A) Reservoir tank

(B) MAX. level

CL-00183

(A)

(B)

(C)

Content .. 703 704 705 706 ..