Subaru Legacy III (2000-2003 year). Manual - part 643

CL-28

CLUTCH SYSTEM

MASTER CYLINDER

C: DISASSEMBLY

1) Remove straight pin and reservoir tank.

2) Remove oil seal.

3) Move the cylinder boot backward.

4) Remove snap ring.

CAUTION:
Be careful when removing the snap ring to pre-
vent the rod, washer, piston and return spring 
from flying out.

D: ASSEMBLY

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

Grease:

SILICONE GREASE G40M (Part No. 
004404003)

2) To assemble the master cylinder reverse the se-
quence of disassembly procedure.

Tightening torque:

T: 10 N·m (1.0 kgf-m, 7 ft-lb)

E: INSPECTION

If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring and gasket, re-
place the faulty part.

(A) Reservoir tank

(B) Straight pin

(A) Oil seal

(B) Master cylinder

(A) Cylinder boot

(B) Master cylinder

CL-00178

( A )

( B )

( A )

( B )

CL-00179

CL-00048

(A)

(B)

(A) Master cylinder body

(B) Return spring

(C) Piston

(D) Snap ring

(E) Rod ASSY

(F) Clutch dumper (Turbo model)

(G) Cylinder boot

CL-00180

CL-00181

(B)

(C)

(D)

(E)

(A)

(F)

(G)

CL-29

CLUTCH SYSTEM

CLUTCH PIPE AND HOSE

7. Clutch Pipe and Hose

A: REMOVAL

1) Remove air cleaner case and air intake duct.
2) Drain clutch fluid. <Ref. to CL-30, Clutch Fluid.>
3) Remove clutch pipe from the clutch hose and
master cylinder.
4) Pull out clamp, then remove clutch hose from
bracket.

5) Remove hose from operating cylinder.

B: INSTALLATION

Install in the reverse order of removal.

NOTE:
Bleed clutch fluid. <Ref. to CL-31, Clutch Fluid Air
Bleeding.>

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)

C: INSPECTION

Check pipes and hoses for cracks, breakage, or
damage. Check joints for fluid leakage. If any
cracks, breakage, damage, or leakage is found, re-
pair or replace the applicable pipe or hose.

(A) Clamp

(B) Clutch hose

CL-00057

( A )

( B )

(A) Clutch pipe (LHD model)

(B) Clamp

(C) Clutch hose

(D) Clutch pipe (RHD model)

CL-00182

T1

T1

T1

T2

( A )

( B )

( B )

( C )

( C )

( C )

( D )

CL-30

CLUTCH SYSTEM

CLUTCH FLUID

8. Clutch Fluid

A: INSPECTION

1) Park vehicle on a level surface.
2) Check the clutch fluid for significant deteriora-
tion. If it is deteriorated, replace it.
3) Inspect the fluid level using the scale on the out-
side of the clutch master cylinder tank. If the level is
below “MIN”, add clutch fluid to bring it up to “MAX”.

B: REPLACEMENT

CAUTION:
• The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
• Cover bleeder with waste cloth, when loosen-
ing it, to prevent brake fluid from being
splashed over surrounding parts.
• Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
• Be careful not to allow dirt or dust to get into
the reservoir tank.

NOTE:
• During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to eliminate entry of
air.
• Clutch pedal operating must be very slow.
• For convenience and safety, it is advisable to
have two men working.
• The amount of brake fluid required is approxi-
mately 70 m

2

 (2.4 US fl oz, 2.5 Imp fl oz) for total

clutch system.
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) Draw out the brake fluid from reservoir tank with
syringe.

4) Refill reservoir tank with recommended brake
fluid.

Recommended brake fluid:

FMVSS No. 116, fresh DOT3 or 4 brake fluid

5) Drain fluid in the same method as the air bleed-
ing.
6) Refill brake fluid before reservoir tank becomes
empty, and drain contaminated fluid again.
7) Repeat the above procedure until the contami-
nated fluid is completely drained.

(A) Reservoir tank

(B) Maximum (MAX) level

(C) Maximum (MIN) level

CL-00183

M

I

N

MA

X

( A )

( B )

( C )

CL-31

CLUTCH SYSTEM

CLUTCH FLUID AIR BLEEDING

9. Clutch Fluid Air Bleeding

A: PROCEDURE

1. NON-TURBO MODEL

NOTE:
Bleed air from oil line with the help of a co-worker.
1) Remove air cleaner case.
<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
2) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.

3) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.

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

CAUTION:
Cover bleeder with waste cloth when loosening 
it, to prevent brake fluid from being splashed 
over surrounding parts.

NOTE:
During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to eliminate entry of
air.
5) Tighten air bleeder.

Tightening torque:

T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)

6) Check the fluid level. <Ref. to CL-30, INSPEC-
TION, Clutch Fluid.>
7) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
8) After bleeding air from system, ensure that
clutch operates properly.
9) Install air cleaner case. <Ref. to IN(H4SO)-6,
REMOVAL, Air Cleaner Case.>

2. TURBO MODEL

NOTE:
Bleed air from the oil line with help of a co-worker.
1) Remove the intercooler. <Ref. to IN(H4DOSTC)-
13, REMOVAL, Intercooler.>
2) Remove the operating cylinder.

NOTE:
Do not remove the clutch hose.

(A) Clutch hose

(B) Air bleeder

(A) Operating cylinder

(B) Vinyl tube

CL-00063

( B )

( A )

CL-00064

( A )

( B )

CL-00065

T

CL-00068