Subaru Legacy III (2000-2003 year). Manual - part 641

CL-20

CLUTCH SYSTEM

FLYWHEEL

3. Flywheel

A: REMOVAL

1. EUROPE AND AUSTRALIA NON-TURBO
MODELS

1) Remove transmission assembly. <Ref. to MT-
32, REMOVAL, Manual Transmission Assembly.>
2) Remove clutch cover and clutch disc. <Ref. to
CL-15, REMOVAL, Clutch Disc and Cover.>
3) Remove flywheel using ST1 and ST2.
ST1

498497100

CRANKSHAFT STOPPER

ST2

499057000

TORX PLUS

2. EXCEPT EUROPE AND AUSTRALIA
NON-TURBO MODELS AND TURBO MOD-
EL

498497100

CRANKSHAFT STOPPER

B: INSTALLATION

1. EUROPE AND AUSTRALIA NON-TURBO
MODELS

1) Install flywheel and ST.

498497100

CRANKSHAFT STOPPER

2) Tighten the flywheel attaching bolts to the spec-
ified torque.
ST

499057000

TORX PLUS

NOTE:
Tighten flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross fashion.

Tightening torque:

72 N·m (7.3 kgf-m, 52.8 ft-lb)

3) Install clutch disc and cover. <Ref. to CL-15, EU-
ROPE AND AUSTRALIA NON-TURBO MODELS,
INSTALLATION, Clutch Disc and Cover.>
4) Install transmission assembly. <Ref. to MT-35,
INSTALLATION, Manual Transmission Assem-
bly.>

(A) Flywheel

ST1

ST2

( A )

CL-00121

CL-00019

( A )

CL-00122

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

CL-00123

CL-21

CLUTCH SYSTEM

FLYWHEEL

2. EXCEPT EUROPE AND AUSTRALIA
NON-TURBO MODELS AND TURBO MOD-
EL

1) Install flywheel and ST.
ST

498497100

CRANKSHAFT STOPPER

2) Tighten the flywheel attaching bolts to the spec-
ified torque.

NOTE:
Tighten flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in
a crisscross fashion.

Tightening torque:

72 N·m (7.3 kgf-m, 52.8 ft-lb)

3) Install clutch disc and cover. <Ref. to CL-16, EX-
CEPT EUROPE AND AUSTRALIA NON-TURBO
MODELS AND TURBO MODEL, INSTALLATION,
Clutch Disc and Cover.>
4) Install transmission assembly. <Ref. to MT-35,
INSTALLATION, Manual Transmission Assem-
bly.>

C: INSPECTION

CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gaso-
line or any solvent.
1) Damage of facing and ring gear
If defective, replace flywheel.
Europe and Australia Non-Turbo models

Except Europe and Australia Non-Turbo
models and Turbo model

2) Smoothness of rotation
Rotate ball bearing applying pressure in thrust di-
rection.
3) If noise or excessive play is noted, replace fly-
wheel.

CL-00020

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

CL-00021

(A) Flywheel

(B) Ring gear

(A) Flywheel

(B) Ring gear

( A )

( B )

CL-00124

CL-00022

( A )

( B )

CL-22

CLUTCH SYSTEM

RELEASE BEARING AND LEVER

4. Release Bearing and Lever

A: REMOVAL

1. NON-TURBO MODEL

1) Remove transmission assembly from vehicle
body.
<Ref. to MT-32, REMOVAL, Manual Transmission
Assembly.>
2) Remove the two clips from clutch release lever
and remove release bearing.

NOTE:
Be careful not to deform clips.
3) Remove release lever seal.

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

5) Remove pivot

2. TURBO MODEL

1) Remove the transmission assembly from vehicle
body. <Ref. to MT-32, REMOVAL, Manual Trans-
mission Assembly.>
2) Remove the clutch release lever from transmis-
sion.
3) Put the clutch release bearing in engine side.

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

B: INSTALLATION

1. NON-TURBO MODEL

NOTE:
Before or during assembling, lubricate the following
points with a light coat of grease.
• Contact surface of lever and pivot
• Contact surface of lever and bearing
• Transmission main shaft spline (Use grease con-
taining molybdenum disulphide.)
• Contact surface of lever and operating cylinder
1) Install pivot.

Tightening torque:

15.7 N·m (1.6 kgf-m, 11.6 ft-lb)

2) While pushing release lever to pivot and twisting
it to both sides, fit retainer spring onto the constrict-
ed portion of pivot.

NOTE:
• Apply grease (SUNLIGHT 2: P/N 003602010) to
contact point of release lever and operating cylin-
der. <Ref. to CL-3, COMPONENT, General De-
scription.>
• Confirm that retainer spring is securely fitted by
observing it through the main case hole.

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

(A) Clutch release lever

(B) Release lever seal

(A) Clutch release lever

(B) Screwdriver

CL-00023

( A )

( B )

CL-00024

( A )

( B )

(A) Clutch release bearing

(A) Release lever

( A )

CL-00025

CL-00026

( A )

CL-23

CLUTCH SYSTEM

RELEASE BEARING AND LEVER

4) Install release lever seal.

5) Install transmission assembly.
<Ref. to MT-35, INSTALLATION, Manual Trans-
mission Assembly.>

2. TURBO MODEL

1) Install the release bearing on transmission.
2) Insert the release fork into release bearing tab.

3) Apply grease to the specified points:
• Spline FX2200 (Part No. 000040901)
• Shaft SUNLIGHT 2 (Part No. 003602010)

4) Insert the release fork shaft into release fork.

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

(A) Release lever

(B) Release lever seal

(A) Release fork

(B) Release bearing

CL-00023

( A )

( B )

( A )

CL-00028

( B )

(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)

(A) Release fork

(B) Release shaft

CL-00029

( A )

( B )

CL-00030

( A )

( B )

( C )

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