Subaru Legacy III (2000-2003 year). Service manual — part 640
CL-16
CLUTCH SYSTEM
CLUTCH DISC AND COVER
2) Install clutch cover on flywheel and tighten bolts
to the specified torque.
NOTE:
• Align matching marks.
• Note the front and rear of the clutch disc when in-
stalling.
• Tighten clutch cover installing bolts gradually.
Each bolt should be tightened to the specified
torque in a crisscross fashion.
Tightening torque:
15.7 N·m (1.6 kgf-m, 11.6 ft-lb)
3) Remove ST.
ST
499747100
CLUTCH DISC GUIDE
4) Install transmission assembly. <Ref. to MT-35,
INSTALLATION, Manual Transmission Assem-
bly.>
2. EXCEPT EUROPE AND AUSTRALIA
NON-TURBO MODELS AND TURBO MOD-
EL
1) Insert ST into the clutch disc and install them on
the flywheel by inserting the ST end into the pilot
bearing.
NOTE:
When installing clutch disc, be careful its direction.
ST
499747100
CLUTCH DISC GUIDE
2) Install clutch cover on flywheel and tighten bolts
to the specified torque.
NOTE:
• When installing the clutch cover on the flywheel,
position the clutch cover so that there is a gap of
120
°
or more between “0” marks on the flywheel
and clutch cover. (“0” marks indicate the directions
of residual unbalance.)
• Note the front and rear of the clutch disc when in-
stalling.
• Temporarily tighten bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
15.7 N·m (1.6 kgf-m, 11.6 ft-lb)
3) Remove ST.
ST
499747100
CLUTCH DISC GUIDE
4) Install transmission assembly. <Ref. to MT-35,
INSTALLATION, Manual Transmission Assem-
bly.>
(A) Flywheel side
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
CL-00115
CL-00012
(A)
ST
(A) “0” marks
( A )
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
ST
CL-00013
CL-17
CLUTCH SYSTEM
CLUTCH DISC AND COVER
C: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of
facing. Replace if facings are worn locally or worn
down to less than the specified value.
Depth of rivet head:
Limit of sinking
0.3 mm (0.012 in)
NOTE:
Do not wash clutch disc with any cleaning fluid.
Europe and Australia Non-Turbo models
Except Europe and Australia Non-Turbo
models and Turbo model
2) Hardened facing
Correct by using emery paper or replace.
3) Oil soakage on facing
Replace clutch disc and inspect transmission front
oil seal, transmission case mating surface, engine
rear oil seal and other points for oil leakage.
Europe and Australia Non-Turbo models
Except Europe and Australia Non-Turbo
models and Turbo model
CL-00116
CL-00014
(A) Clutch facing
(A) Clutch facing
( A )
CL-00117
CL-00015
( A )
CL-18
CLUTCH SYSTEM
CLUTCH DISC AND COVER
4) Deflection on facing
If deflection exceeds the specified value at the out-
er circumference of facing, repair or replace.
ST
499747100
CLUTCH DISC GUIDE
Limit for deflection:
Non-Turbo model
1.0 mm (0.039 in) at R = 107 mm (4.21 in)
Turbo model
0.8 mm (0.03 in) at R = 110 mm (4.33 in)
Europe and Australia Non-Turbo models
Except Europe and Australia Non-Turbo
models and Turbo model
5) Worn spline, loose rivets and torsion spring fail-
ure
Replace defective parts.
Europe and Australia Non-Turbo models
Except Europe and Australia Non-Turbo
models and Turbo model
2. CLUTCH COVER
NOTE:
Visually check for the following items without disas-
sembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at center
of diaphragm spring.
Europe and Australia Non-Turbo models
Except Europe and Australia models
(A) Spline
(B) Rivet
(C) Torsion spring
ST
CL-00118
CL-00016
ST
( A )
( B )
CL-00119
(A) Spline
(B) Rivet
(C) Torsion spring
(A) Thrust rivet
(B) Diaphragm spring
(A) Thrust rivet
(B) Diaphragm spring
CL-00017
( B )
( C )
( A )
( A )
( B )
CL-00120
CL-00018
( A )
( B )
CL-19
CLUTCH SYSTEM
CLUTCH DISC AND COVER
3) Damaged or worn disc contact surface of pres-
sure plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.
Europe and Australia Non-Turbo models
Except Europe and Australia Non-Turbo
models and Turbo model
(A) Pressure plate
(B) Strap plate
(A) Pressure plate
(B) Strap plate
CL-00176
( A )
( B )
CL-00177
( A )
( B )
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