Subaru Legacy III (2000-2003 year). Manual - part 642

CL-24

CLUTCH SYSTEM

RELEASE BEARING AND LEVER

5) Tighten the plug.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

6) Install the transmission assembly. <Ref. to MT-
35, INSTALLATION, Manual Transmission Assem-
bly.>

C: INSPECTION

1. RELEASE BEARING

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

Radial direction stroke:

1.4 mm (0.055 in)

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

3) Check wear and damage of bearing case sur-
face contacting with  lever.

2. RELEASE LEVER

1) Check lever pivot portion and the point of contact
with release  bearing case for wear.

(A) Bearing case

CL-00031

CL-00032

( A )

(A) Bearing case

(A) Clutch release lever

(B) Pivot

(C) Clutch release bearing

CL-00136

( A )

CL-00034

( A )

( B )

( C )

CL-25

CLUTCH SYSTEM

OPERATING CYLINDER

5. Operating Cylinder

A: REMOVAL

1) Remove air cleaner case. (Non-Turbo model)
<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
2) Remove intercooler. (Turbo model)
<Ref. to IN(H4DOSTC)-13, REMOVAL, Intercool-
er.>
3) Remove clutch hose from operating cylinder.

CAUTION:
Cover hose joint to prevent clutch fluid from 
flowing out.
• Non-Turbo model

• Turbo model

4) Remove operating cylinder from transmission.
• Non-Turbo model

• Turbo model

B: INSTALLATION

1) Install in the reverse order of removal.

NOTE:
Before installing operating cylinder, apply grease
(SUNLIGHT 2: P/N 003602010) to contact point of
release lever and operating cylinder.

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)

• Non-Turbo model

(A) Clutch hose

(B) Operating cylinder

(A) Clutch hose

(B) Operating cylinder

CL-00035

( A )

( B )

CL-00036

( B )

( A )

(A) Operating cylinder

CL-00037

CL-00038

( A )

CL-00039

T1

T2

T2

CL-26

CLUTCH SYSTEM

OPERATING CYLINDER

• Turbo model

NOTE:
• Install the clutch hose facing mark upward.
• Do not twist clutch hose while installing.

2) After bleeding air from operating cylinder, en-
sure that clutch operates properly.
<Ref. to CL-31, Clutch Fluid Air Bleeding.>

C: INSPECTION

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

(A) Mark

(B) Clutch hose

(C) Operating cylinder

CL-00040

T1

T2

( A )

( B )

( C )

CL-00041

CL-27

CLUTCH SYSTEM

MASTER CYLINDER

6. Master Cylinder

A: REMOVAL

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

3) Remove air cleaner case. (Non-Turbo model)
<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
4) Remove intercooler. (Turbo model) <Ref. to
IN(H4DOSTC)-13, REMOVAL, Intercooler.>
5) Remove clutch pipe from master cylinder.
6) Remove master cylinder with reservoir tank.

CAUTION:
Be extremely careful not to spill brake fluid. 
Brake fluid spilt on the vehicle body will harm 
the paint surface; wipe it off quickly if spilt.

B: INSTALLATION

1) Install master cylinder to body, and install clutch
pipe to master cylinder.

CAUTION:
Check that 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 push rod of master cylinder to clutch
pedal, and install clevis pin and snap pin.

NOTE:
Apply grease to clevis pin.

3) After bleeding air from system, ensure that
clutch operates properly.
<Ref. to CL-31, Clutch Fluid Air Bleeding.>
4) Install air cleaner case.  (Non-Turbo model)
<Ref. to IN(H4SO)-6, INSTALLATION, Air Cleaner
Case.>
5) Install intercooler. (Turbo model)
<Ref. to IN(H4DOSTC)-14, INSTALLATION, Inter-
cooler.>

(A) Clevis pin

(B) Snap pin

(C) Push rod

(D) Lock nut

(A) Master cylinder

(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 )