Subaru Legacy IV (2008 year). Service manual — part 838
CL-38
Clutch Switch
CLUTCH SYSTEM
C: INSPECTION
1) Make sure that engine does not start with clutch
pedal not depressed. If the engine starts, adjust the
clutch switch and inspect the starter interlock cir-
cuit.
2) Make sure that the engine starts with the clutch
pedal fully depressed. If the engine does not start,
adjust the clutch switch and inspect the starter in-
terlock circuit.
3) Check the clutch switch for continuity. If the re-
sistance is not at the standard value, replace the
switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between terminal 1
and 2 of the switch.
Clutch switch (Clutch start)
Clutch switch (Cruise control)
D: ADJUSTMENT
1) Loosen the lock nut of clutch switch (clutch
start).
2) Fully depress the clutch pedal and hold it.
3) Adjust the gap of the clutch pedal plate and the
clutch switch to be 3.1 — 4.1 mm (0.12 — 0.16 in).
4) Tighten the lock nut.
Tightening torque:
8 N·m (0.8 kgf-m, 5.9 ft-lb)
Condition
Terminal No.
Specified resistance
When the clutch
pedal is depressed
1 and 2
Less than 1
:
Except when the
clutch the pedal is
depressed
1 and 2
1 M
: or more
CL-00102
1
2
CL-00084
2 1
(A) Lock nut
(B) Clutch switch (Clutch start)
(A) Plate
(B) Clutch switch (Clutch start)
(C) 3.1 — 4.1 mm (0.12 — 0.16 in)
(A)
(B)
CL-00537
(A)
(B)
(C)
CL-00104
CL-39
General Diagnostic Table
CLUTCH SYSTEM
12.General Diagnostic Table
A: INSPECTION
1. CLUTCH
Symptom
Possible cause
Corrective action
1. Clutch slippage.
It is hard to perceive clutch slippage in the early stage, but
pay attention to the following symptoms.
• Engine speeds up when shifting.
• High-speed driving is not possible; especially rapid
acceleration is not possible and vehicle speed does not
increase in proportion to the increase in engine speed.
• Power drops particularly when ascending a slope, and
there is a burning smell of the clutch plate.
• Method of testing: Park the vehicle and fully apply the
parking brake. Disengage the clutch and shift the transmis-
sion gear into the 1st. Gradually increase the engine speed
while gradually allowing the clutch to engage. The clutch
function is satisfactory if the engine stalls. However, the
clutch is slipping if the vehicle does not move forward and
the engine does not stall.
(a) Oil on the clutch face
Replace.
(b) Worn clutch face
Replace.
(c) Deteriorated diaphragm
spring
Replace.
(d) Warped pressure plate or fly-
wheel
Repair or replace.
(e) Defective release bearing
holder
Repair or replace.
2. Clutch drags.
As a symptom of this trouble, a harsh scratching noise
occurs and control becomes difficult when shifting gears.
The symptom becomes more apparent when shifting into
the 1st gear. However, because most trouble of this sort is
due to a defective synchronization mechanism, perform
the following tests.
Method of testing:<Ref. to CL-40, DIAGNOSTIC DIA-
GRAM OF CLUTCH DRAG, INSPECTION, General Diag-
nostic Table.>
The problem is caused by insufficient disengagement of
the clutch if an abnormal noise occurs during this test.
(a) Worn or rusty clutch disc hub
spline
Replace the clutch disc.
(b) Excessive deflection of clutch
disc face
Repair or replace.
(c) Crankshaft pilot needle bear-
ing sticking
Replace.
(d) Cracked clutch disc face
Replace.
(e) Stuck clutch disc (smeared
by oil or water)
Replace.
3. Clutch chatters.
Clutch chattering is an unpleasant vibration to the whole
vehicle when the vehicle is just started with clutch partially
engaged.
(a) Adhesion of oil on the clutch
face
Replace the clutch disc.
(b) Weak or broken damper
spring
Replace the clutch disc.
(c) Poor contact of the disc sur-
face or excessively worn disc
Replace the faulty clutch disc.
(d) Warped pressure plate or fly-
wheel
Repair or replace.
(e) Loose disc rivets
Replace the clutch disc.
(f) Loose engine mounting
Retighten or replace mounting.
(g) Improper adjustment of the
pitching stopper
Adjust.
4. Noisy clutch
Examine whether the noise is generated when the clutch is
disengaged, engaged, or partially engaged.
(a) Broken, worn or insufficiently
lubricated release bearing
Replace the release bearing.
(b) Insufficient lubrication of the
pilot bearing
Replace the pilot bearing.
(c) Loose clutch disc hub
Replace the clutch disc.
(d) Loose damper spring retainer Replace the clutch disc.
(e) Deteriorated or broken
damper spring
Replace the clutch disc.
CL-40
General Diagnostic Table
CLUTCH SYSTEM
2. CLUTCH PEDAL
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
5. Clutch grabs suddenly.
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 the clutch disc.
(b) Deteriorated cushioning
spring
Replace the 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
damper spring
Replace the clutch disc.
(e) Loose engine mounting
Retighten or replace mounting.
(f) Deteriorated diaphragm
spring
Replace.
Symptom
Corrective action
Insufficient pedal play
Adjust the free play of the pedal.
Insufficient clutch pedal free play
Adjust the free play of the pedal.
Excessively worn and damaged pedal shaft and/or bushing Replace the bushing or shaft with a new part.
Step
Check
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 there any abnormal noise
from the transmission gear?
Go to step 2.
Clutch is normal.
2
CHECK GEAR NOISE.
Disengage the clutch at idle and shift from neu-
tral to reverse within 0.5 — 1.0 seconds.
Is there any abnormal noise
from the transmission gear?
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.
1) Disengage the clutch at idle and shift from
neutral to reverse within 0.5 — 1.0 seconds.
2) With the clutch disengaged, shift from neu-
tral to reverse, reverse to neutral several times.
Is there any abnormal noise
from the transmission gear?
Inadequate clutch
disengage. Inspect
the clutch disc,
clutch cover, clutch
release, and clutch
pedal free play.
Clutch and fly-
wheel seizure.
Inspect the clutch
disc and the spline
of the clutch disc
hub.
Symptom
Possible cause
Corrective action
FS-2
General Description
FRONT SUSPENSION
1. General Description
A: SPECIFICATION
*1
: OUTBACK model
–3 — 0 mm (–0.12 — 0 in) Toe angle (sum of both wheels): –0°15
c — 0°
*2
: Except for OUTBACK model
0
r3 mm (0r0.12 in) Toe angle (sum of both wheels): 0°r0°15c
NOTE:
• Front and rear toe-in and front camber can be
adjusted. Adjust if the toe-in or camber tolerance
exceeds specifications.
• Other items indicated in the specifications table
cannot be adjusted. If other items exceed specifica-
tions, check the suspension parts and connections
for deformation, and replace with new parts as re-
quired.
Model
Sedan
Wagon
2.5 i
2.5 GT spec.B,
3.0 R
2.5 GT spec.B,
3.0 R-LTD
2.5 i
2.5 GT
OUTBACK
Front
Wheel arch height
(Tolerance:
+12 mm
–24 mm
(
+0.47 in
–0.94 in
))
mm (in)
381 (15.0)
439 (17.3)
Camber (Tolerance:
r0°45c Differences
between RH and LH: 45
c or less)
–0°15
c
0°40
c
Caster (Referential Value)
5°55
c
5°40
c
4°55
c
Steering angle
(Tolerance:
r1.5°)
Inner
wheel
37.6°
33.8°
37.6°
Outer
wheel
33.0°
30.2°
33.0°
Toe-in
mm (in)
0
r3 (0r0.12) Toe angle (sum of both wheels): 0°r0°15c
Kingpin angle (Referential Value)
13°45
c
12°05
c
Rear
Wheel arch height
(Tolerance:
+12 mm
–24 mm
(
+0.47 in
–0.94 in
))
mm (in)
365 (14.4)
375 (14.8)
438 (17.2)
Camber (Tolerance:
r0°45c Differences
between RH and LH: 45
c or less)
–0°40
c
–0°30
c
–0°10
c
Toe-in
mm (in)
*2
*1
Thrust angle (Tolerance:
r0°30c)
0°
(1) Front
A – B = Positive: Toe-in, Negative: Toe-out
D = Individual toe angles
B
A
(1)
FS-00269
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