Subaru Legacy III (2000-2003 year). Manual - part 646

CL-40

CLUTCH SYSTEM

CLUTCH SWITCH

11.Clutch Switch

A: REMOVAL

1) Disconnect the ground cable from battery.
2) Remove the instrument panel lower cover.
3) Disconnect the connector from clutch start
switch.

B: INSTALLATION

1) Install the clutch switch and clutch pedal stopper
so that the gap between them is 0 mm (0 in).

Tightening torque:

8 N·m (0.8 kgf-m, 5.8 ft-lb)

2) Measure stroke of clutch pedal.

Specified clutch pedal full stroke: A

130 — 135 mm (5.12 — 5.31 in)

3) If the clutch pedal stroke is out of specification,
adjust the stroke.<Ref. to CL-37, ADJUSTMENT,
Clutch Pedal.>
4) Connect clutch switch connector.

C: INSPECTION

1) Check the clutch switch continuity. If continuity is
not as specified, replace the switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between 1 and 2 of
switch terminal.
3) Check clutch switch continuity. If continuity is not
as specified, replace the switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between 1 and 2 of
switch terminal.

Terminals/Specified resistance

When clutch pedal depressed:

1 — 2/Less than 1

Ω

Ω

Ω

Ω

Terminals / Specified resistance

When clutch pedal not depressed:

1 — 2/More than 1 M

Ω

Ω

Ω

Ω

D: ADJUSTMENT

Refer to “ADJUSTMENT” for clutch pedal. <Ref. to
CL-37, ADJUSTMENT, Clutch Pedal.>

(A) Clutch switch

(B) Stopper

(C) 0 mm (0 in)

(A)

(B)

(C)

CL-00133

CL-00078

(A)

(B)

(C)

A

CL-00084

2 1

CL-41

CLUTCH SYSTEM

GENERAL DIAGNOSTIC TABLE

12.General Diagnostic Table

A: INSPECTION

1. CLUTCH

Symptom

Possible cause

Corrective

1. Clutch slippage.
It is hard to perceive clutch slippage in the early stage, but 
pay attention to the following symptoms
• Engine speed up  when shifting.
• High speed driving is impossible; especially  rapid 
acceleration impossible and vehicle speed does not 
increase in  proportion to an increase in engine speed.
• Power falls,  particularly when ascending a slope, and 
there is a smell of burning of  the clutch facing.
• Method of testing: Put the vehicle in  stationary condi-
tion with parking brake fully applied. Disengage the  
clutch and shift the transmission gear into the first. Gradu-
ally allow  the clutch to engage while gradually increasing 
the engine speed. The  clutch function is satisfactory if the 
engine stalls. However, the  clutch is slipping if the vehicle 
does not start off and the engine  does not stall.

(a) Clutch  facing smeared by oil

Replace.

(b) Worn clutch facing

Replace.

(c) Deteriorated diaphragm 
spring

Replace.

(d) Distorted pressure plate or fly-
wheel

Correct or  replace.

(e) Defective release bearing 
holder

Correct or  replace.

2. Clutch drags.
As a symptom of this  trouble, a harsh scratching noise 
develops and control becomes quite  difficult when shift-
ing gears. The symptom becomes more apparent when  
shifting into the first gear. However, because much trou-
ble of this sort is due to defective synchronization mecha-
nism, carry out the test  as described after.
• Method of testing: <Ref. to CL-42, DIAGNOSTIC DIA-
GRAM OF CLUTCH DRAG, INSPECTION, General Diag-
nostic Table.>
It may be judged as insufficient disengagement of clutch  
if any noise occurs during this test.

(a) Worn or rusty clutch disc hub 
spline

Replace clutch disc.

(b) Excessive deflection of clutch 
disc  facing

Correct or replace.

(c) Seized crankshaft pilot needle  
bearing

Replace.

(d) Cracked clutch disc facing

Replace.

(e) Sticked clutch disc (smeared 
by oil or water)

Replace.

3. Clutch chatters.
Clutch chattering is  an unpleasant vibration to the whole 
body when the vehicle is just  started with clutch partially 
engaged.

(a) Adhesion of oil on the  facing

Replace clutch disc.

(b) Weak or broken torsion spring Replace clutch disc.

(c) Defective facing contact or 
excessive disc 

Replace clutch disc defection.

(d) Warped  pressure plate or fly-
wheel

Correct or replace.

(e) Loose disc rivets

Replace clutch disc.

(f) Loose engine mounting

Retighten or replace mounting.

(g) Faulty  pitching stopper

Replace.

4. Noisy clutch
Examine whether the noise is  generated when the clutch 
is disengaged, engaged, or partially engaged.

(a) Broken, worn or unlubricated 
release bearing

Replace  release bearing.

(b) Insufficient lubrication of pilot 
bearing

Apply grease.

(c) Loose clutch disc hub

Replace clutch  disc.

(d) Loose torsion spring retainer

Replace clutch  disc.

(e) Deteriorated or broken torsion 
spring

Replace clutch  disc.

CL-42

CLUTCH SYSTEM

GENERAL DIAGNOSTIC TABLE

2. CLUTCH PEDAL

3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

5. Clutch grabs.
When starting the vehicle  with the clutch partially 
engaged, the clutch engages suddenly and the  vehicle 
jumps instead of making a smooth start.

(a) Grease or oil  on facing

Replace clutch disc.

(b) Deteriorated cushioning  
spring

Replace clutch disc.

(c) Worn or rusted spline of  
clutch disc or main shaft

Take off rust, apply grease or 
replace clutch  disc or main shaft.

(d) Deteriorated or broken torsion  
spring

Replace clutch disc.

(e) Loose engine mounting

Retighten or replace mounting.

(f) Deteriorated diaphragm  
spring

Replace.

Trouble

Corrective action

Insufficient pedal play

Adjust pedal play.

Clutch pedal free play insufficient

Adjust pedal free play.

Excessively worn and damaged pedal shaft and/or bushing

Replace bushing and/or shaft with new one.

Step

Value

Yes

No

1

CHECK GEAR NOISE.
1) Start the engine.
2) Disengage the clutch and shift quickly from 

neutral to reverse in idling condition.

Is an abnormal noise heard 
from the transmission gears?

Go to step 2.

Clutch is normal.

2

CHECK GEAR NOISE.
With the engine idling, disengage the clutch 
and shift quickly (between 0.5 to 1.0 s) from 
neutral to reverse.

Is an abnormal noise heard 
from the transmission gears?

Go to step 3.

Defective trans-
mission or exces-
sive clutch drag 
torque. Inspect 
pilot bearing, 
clutch disc, trans-
mission and clutch 
disc hub spline.

3

CHECK GEAR NOISE.
With the engine idling, disengage the clutch 
and shift quickly (between 0.5 to 1.0 s) from 
neutral to reverse shift repeatedly between 
neutral and reverse with clutch disengaged.

Is an abnormal noise heard 
from the transmission gears?

Clutch is not dis-
engaged properly. 
Inspect clutch 
disc, clutch cover, 
clutch release sys-
tem, and clutch 
pedal free play.

Clutch disc and fly-
wheel are locked 
together. Inspect 
clutch disc and 
clutch disc hub 
spline.

Symptom

Possible cause

Corrective

FUJI HEAVY INDUSTRIES LTD.

G2300GE6

2003 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FRONT SUSPENSION

FS

REAR SUSPENSION

RS

WHEEL AND TIRE SYSTEM

WT

DIFFERENTIALS

DI

TRANSFER CASE

TC

DRIVE SHAFT SYSTEM

DS

ABS

ABS

ABS (DIAGNOSTICS)

ABS

VDC

VDC

VDC (DIAGNOSTICS)

VDC

BRAKE

BR

PARKING BRAKE

PB

POWER ASSISTED SYSTEM 
(POWER STEERING)

PS