Subaru Legacy III (2000-2003 year). Manual - part 645

CL-36

CLUTCH SYSTEM

CLUTCH PEDAL

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

D: ASSEMBLY

1. LHD MODEL

1) Attach clutch switch, etc. to pedal bracket tem-
porarily.
2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach brake pedal return spring, as-
sist rods, and spring, and bushing.

NOTE:
Clean up inside of bushings and apply grease be-
fore installing spacer.
4) Install hill holder cable to the clutch pedal. (Vehi-
cle with hill holder)

2. RHD MODEL

1) Clean and apply grease to hole of sliding portion
between clutch pedal and bushing.
2) Install pad, stopper, bushing C, spacer and
bushing to clutch pedal.
3) Install rod S, spring S, bushing S, clip, bushing,
clutch switch and bushing C to clutch pedal brack-
et.

4) Install clutch pedal to pedal bracket.

Tightening torque:

T: 29 N·m (3.0 kgf-m, 21.7 ft-lb)

5) Install assist rod, bushing and assist spring to
clutch pedal and pedal bracket.
6) Install PHV cable to clutch pedal. (Vehicle with
hill holder).

E: INSPECTION

1.  CLUTCH PEDAL

Move clutch pedal pads in the lateral direction with
a force of approximately 10 N (1 kgf, 2 lb) to ensure
pedal deflection is in specified range.
If excessive deflection is noted, replace bushings
with new ones.

Deflection of clutch pedal:

Service limit

5.0 mm (0.197 in) or less

(A) Spacer

(B) Bushing

(C) Bushing

(D) Pedal pad

(E) Clutch pedal

(F) Bushing C

( A )

( B )

( B )

( C )

( D )

( E )

( F )

( F )

CL-00130

(A) Clutch pedal

(B) Brake pedal

CL-00185

T

CL-00098

( A )

( B )

CL-37

CLUTCH SYSTEM

CLUTCH PEDAL

F: ADJUSTMENT

1. LHD MODEL

1) Measure the full stroke amount of clutch pedal.

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

Specified clutch pedal full stroke: A

130 — 135 mm (5.12 — 5.31 in)

2) If not as specified, loosen the clutch stopper nut
to adjust it.

Tightening torque (Clutch stopper nut):

8 N·m (0.8 kgf-m, 5.8 ft-lb)

3) Loosen the push rod lock nut.

4) Turn the push rod to adjust.

(1) Ensure that the clutch pedal contacts stop-
per bolt, 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 clockwise to shorten until
clearance is made at stopper bolt or clutch switch.
• Without cruise control

• With cruise control

(A) Clutch (Ful stroke condition)

(B) Scale

(C) Seat

(A) Clevis pin

(B) Snap pin

(C) Push rod

(D) Push rod lock nut

CL-00078

(A)

(B)

(C)

A

CL-00042

( A )

( B )

( C )

( D )

(A) Clevis hole

(B) Push rod lock nut

(C) Lengthening direction

(D) Shortening direction

(E) Push rod

(F) U shaped bracket

(A) Stoper

(B) Stopper bolt

(A) Clutch switch

(B) Stopper

(C) Clearance

CL-00080

(B)

(A)

(C)

(D)

(E)

(F)

(A)

(B)

CL-00131

(A)

(B)

(C)

CL-00132

CL-38

CLUTCH SYSTEM

CLUTCH PEDAL

6) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt or clutch
switch.
7) Turn the push rod further 270× counterclockwise
to lengthen (arrow direction as shown in the figure).

8) Move the clevis pin in lateral direction to ensure
it moves smoothly.
9) Tighten the push rod lock nut.

Tightening torque (Clutch stopper nut):

10 N·m (1.0 kgf-m, 7.2 ft-lb)

10) Measure the full stroke amount of clutch pedal
again.

Specified clutch pedal full stroke: A

130 — 135 mm (5.12 — 5.31 in)

11) Install the clutch switch. <Ref. to CL-40, IN-
STALLATION, Clutch Switch.>

2. RHD MODEL

1) Measure the full stroke amount of clutch pedal.

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

Specified clutch pedal full stroke: A

130 — 135 mm (5.12 — 5.31 in)

2) If not as specified, adjust it with stopper bolt or
clutch switch.

Tightening torque (Clutch stopper nut):

8 N·m (0.8 kgf-m, 5.8 ft-lb)

3) Loosen the push rod lock nut.

4) Turn the push rod to adjust.

(1) Ensure that the clutch pedal contacts stop-
per bolt, when releasing the clutch pedal.

(A) Accelerator pedal

(B) Clevis

CL-00101

(B)

(A)

(A) Clutch (Ful stroke condition)

(B) Scale

(C) Seat

(A) Clevis pin

(B) Snap pin

(C) Push rod

(D) Push rod lock nut

CL-00078

(A)

(B)

(C)

A

CL-00042

( A )

( B )

( C )

( D )

CL-39

CLUTCH SYSTEM

CLUTCH PEDAL

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

5) Turn the push rod clockwise to shorten until
clearance is made at stopper bolt or clutch switch.

6) Turn the push rod counter clockwise to lengthen
until clutch pedal contacts to stopper bolt or clutch
switch.
7) Turn the push rod further 270× counterclockwise
to lengthen (arrow direction as shown in the figure).

8) Move the clevis pin in lateral direction to ensure
it moves smoothly.
9) Tighten the push rod lock nut.

Tightening torque (Clutch stopper nut):

10 N·m (1.0 kgf-m, 7.2 ft-lb)

10) Measure the full stroke amount of clutch pedal
again.

Specified clutch pedal full stroke: A

130 — 135 mm (5.12 — 5.31 in)

11) Install the clutch switch. <Ref. to CL-40, IN-
STALLATION, Clutch Switch.>

(A) Clevis hole

(B) Push rod lock nut

(C) Lengthening direction

(D) Shortening direction

(E) Push rod

(F) U shaped bracket

(A) Stopper bolt

(A) Clutch pedal

(B) Brake pedal

CL-00080

(B)

(A)

(C)

(D)

(E)

(F)

CL-00134

(A)

CL-00085

(A)

(B)