Subaru Legacy IV (2008 year). Manual - part 837

CL-34

Clutch Pedal

CLUTCH SYSTEM

F: ADJUSTMENT

1) Measure the full stroke of the clutch pedal.

NOTE:
• Measure the leading end of the seat cushion and
center of the pedal.
• Align the seat with the seventh notch position
from the position at the very front.

Specified clutch pedal full stroke A:

5MT non-turbo model and 6MT model:

130 — 135 mm (5.12 — 5.31 in)

5MT turbo model:

135 — 140 mm (5.31 — 5.51 in)

2) If the full stroke is not within the specified value,
loosen the clutch switch lock nut to adjust.

Tightening torque:

8 N·m (0.8 kgf-m, 5.9 ft-lb)

3) Loosen the push rod lock nuts.

4) Rotate the push rod to adjust.

(1) Make sure that the clutch pedal contacts the
clutch switch side when the pedal is released.
(2) Make sure that the clutch pedal contacts the
clutch pedal bracket stopper when the clutch
pedal is at the maximum stroke position.

5) Turn the push rod to shorten until a clearance is
gained on the clutch switch side.

6) Turn the push rod to lengthen until clutch pedal
contacts the clutch switch.

A Measured value

(A) Clutch pedal (Full stroke condition)

(B) Scale

(A) Clevis pin

(B) Snap pin

(D) Push rod lock nut

CL-00078

(A)

(B)

(C)

CL-00042

(A)

(B)

(C)

(D)

(A) Clevis hole

(B) Push rod lock nut

(D) In the longer direction

(E) Push rod

(F) U shaped hardware

(A) Clutch switch

(B) Stopper

CL-00080

(B)

(A)

(C)

(D)

(E)

(F)

(A)

(B)

(C)

CL-00538

CL-35

Clutch Pedal

CLUTCH SYSTEM

7) Turn further in the direction that will shorten the
push rod (arrow direction shown in figure) by 270°.

8) Check that the clevis pin moves smoothly by
moving it in the left and right directions.
9) Tighten the push rod lock nut.

Tightening torque:

10 N·m (1.0 kgf-m, 7.4 ft-lb)

10) Depress and release the clutch pedal two or
three times to ensure that the clutch pedal and re-
lease fork operate smoothly. If the clutch pedal and
release fork do not operate smoothly, bleed air
from the clutch hydraulic system. <Ref. to CL-30,
Clutch Fluid Air Bleeding.>
11) Measure the clutch pedal full stroke length
again to ensure that it is within specifications. If it is
not within specifications, repeat adjustment proce-
dures again from the beginning.

Specified clutch pedal full stroke:

5MT non-turbo model and 6MT model:

130 — 135 mm (5.12 — 5.31 in)

5MT turbo model:

135 — 140 mm (5.31 — 5.51 in)

12) Move the clevis pin to left, then to right. The cle-
vis pin should move without resistance even if it is
rattling. If resistance is felt, repeat adjustment pro-
cedures again from the beginning.

13) Push the release lever until the operating cylin-
der push rod retracts. Make sure that the clutch flu-
id level in the reservoir tank increases. If the clutch
fluid level increases, the hydraulic clutch is properly
adjusted;if the fluid level does not increase or the
push rod does not retract, replace the master cylin-
der. <Ref. to CL-25, Master Cylinder.>
• 5MT model

NOTE:
The illustration below is for a Non-turbo model.
However, perform the same procedures for the
Turbo model.

• 6MT model

(A) Accelerator pedal

(B) Clevis

CL-00101

(B)

(A)

(1) Push rod

(2) Release lever

(3) Operating cylinder

(1) Push rod

(2) Release lever

(3) Operating cylinder

CL-00371

(1)

(3)

(2)

CL-00448

(1)

(2)

(3)

CL-36

Clutch Pedal

CLUTCH SYSTEM

14) Check the fluid level using the scale on the out-
side of the reservoir tank. If the level is below MIN,
fill fluid up to MAX level.

Recommended clutch fluid:

FMVSS No. 116, fresh DOT3 brake fluid

(A) Reservoir tank

(B) MIN. level

CL-00159

M I N

MAX

( A )

( C )

( B )

CL-37

Clutch Switch

CLUTCH SYSTEM

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 switch.
4) Remove the clutch switches.

B: INSTALLATION

1. CLUTCH SWITCH (WITH CRUISE
CONTROL)

1) Install so that there is a gap of 0 mm (0 in) of the
clutch switch and clutch pedal stopper.

Tightening torque:

8 N·m (0.8 kgf-m, 5.9 ft-lb)

2) Measure the stroke of the clutch pedal.

Clutch pedal standard full stroke: A

5MT non-turbo model and 6MT model

130 — 135 mm (5.12 — 5.31 in)

5MT turbo model

135 — 140 mm (5.31 — 5.51 in)

3) If the clutch pedal stroke is out of specification,
adjust the stroke. <Ref. to CL-34, ADJUSTMENT,
Clutch Pedal.>
4) Connect the clutch switch connector.

2. CLUTCH SWITCH (CLUTCH START)

1) Fully depress the clutch pedal and hold it.
2) Install the clutch pedal plate and clutch pedal so
that the gap between them is 3.1 — 4.1 mm (0.12
— 0.16 in), and then tighten the lock nut.

Tightening torque:

8 N·m (0.8 kgf-m, 5.9 ft-lb)

3) Connect the clutch switch connector.
4) Make sure that engine does not start with clutch
pedal not depressed.
5) Make sure that the engine starts with the clutch
pedal fully depressed.

(A) Clutch switch

(B) Stopper

A Measured value

(A) Clutch pedal (Full stroke condition)

(B) Scale

(A)

(B)

(C)

CL-00536

CL-00078

(A)

(B)

(C)

(A) Plate

(B) Clutch pedal

(A)

(B)

(C)

CL-00104

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