Subaru Legacy (2005 year). Service manual — part 699
CL-15
CLUTCH SYSTEM
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
REMARKS
498497100
CRANKSHAFT
STOPPER
Used for stopping rotation of flywheel when loos-
ening/tightening bolt, etc.
499747100
CLUTCH DISC
GUIDE
Used for installing clutch disc to flywheel.
499057000
TORX PLUS
®
Used for removing flywheel (dual mass flywheel
type).
TOOL NAME
REMARKS
Circuit tester
Used for measuring resistance, voltage and ampere.
Dial gauge
Used for measuring clutch disc run-out.
Depth gauge
Used for measuring wear of clutch disc.
ST-498497100
ST-499747100
ST-499057000
CL-16
CLUTCH SYSTEM
Clutch Disc and Cover
2. Clutch Disc and Cover
A: REMOVAL
1. 5MT EC, EK AND KA MODEL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 5MT-30, REMOVAL, Manual Trans-
mission Assembly.>
2) Insert the ST to flywheel.
ST
499747100
CLUTCH DISC GUIDE
3) Remove the clutch cover and clutch disc.
NOTE:
• Take care not to allow oil on the clutch disc fac-
ing.
• Do not disassemble the clutch cover or clutch
disc.
• Be sure to put alignment marks on the flywheel
and clutch cover before removing clutch cover.
2. 5MT KS, K4, TURBO MODEL AND 6MT
MODEL
1) Remove the transmission assembly from vehi-
cle. <Ref. to 5MT-30, REMOVAL, Manual Trans-
mission Assembly.> <Ref. to 6MT-34, REMOVAL,
Manual Transmission Assembly.>
2) Install the ST to flywheel.
ST
499747100
CLUTCH DISC GUIDE
3) Remove the clutch cover and clutch disc.
NOTE:
• Take care not to allow oil on the clutch disc fac-
ing.
• Do not disassemble the clutch cover or clutch
disc.
B: INSTALLATION
1. 5MT EC, EK AND KA MODEL
1) Insert the ST into clutch disc, and install on the
flywheel by inserting the ST end into pilot bearing.
NOTE:
When installing the clutch disc, be careful to its di-
rection.
ST
499747100
CLUTCH DISC GUIDE
2) Install the 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 the paint marks “
” on the
flywheel and clutch cover. (the paint marks “
”
indicate the directions of residual unbalance.)
• Note the front and rear of the clutch disc when in-
stalling.
(A) Dual mass flywheel
CL-00112
( A )
ST
CL-00113
(A) Clutch cover
(A) Flywheel side
CL-00011
( A )
S T
CL-00282
(A)
ST
(A)
CL-17
CLUTCH SYSTEM
Clutch Disc and Cover
• Tighten the clutch cover installing bolts gradual-
ly. Each bolt should be tightened to the specified
torque in a crisscross order.
Tightening torque:
16 N
⋅
m (1.6 kgf-m, 11.8 ft-lb)
3) Remove the ST.
ST
499747100
CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to 5MT-
32, INSTALLATION, Manual Transmission Assem-
bly.>
2. 5MT KS, K4, TURBO MODEL AND 6MT
MODEL
1) Insert the ST into clutch disc, and install on the
flywheel by inserting the ST end into pilot bearing.
NOTE:
When installing the clutch disc, be careful to its di-
rection.
ST
499747100
CLUTCH DISC GUIDE
2) Install the clutch cover on flywheel and tighten
the 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 the paint marks “
” on the
flywheel and clutch cover. (the paint marks “
”
indicate the directions of residual unbalance.)
• Note the front and rear of the clutch disc when in-
stalling.
• Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross order.
Tightening torque:
16 N
⋅
m (1.6 kgf-m, 11.8 ft-lb)
3) Remove the ST.
ST
499747100
CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to 5MT-
32, INSTALLATION, Manual Transmission Assem-
bly.> <Ref. to 6MT-36, INSTALLATION, Manual
Transmission Assembly.>
C: INSPECTION
1. CLUTCH DISC
1) Wear of facing:
Measure the depth from the surface of facing to riv-
et head. Replace if the 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 the clutch disc with any cleaning fluid.
(A) Flywheel side
CL-00115
(1)
(2)
(3)
(4)
(5)
(6)
CL-00208
(A)
ST
(A) “0” mark
CL-00013
( A )
S T
( 2 )
( 5 )
( 3 )
( 1 )
( 6 )
( 4 )
CL-18
CLUTCH SYSTEM
Clutch Disc and Cover
• 5MT EC, EK and KA model
• 5MT KS, K4 model and 6MT model
• 5MT turbo model
2) Hardened facing
Replace the clutch disc.
3) Oil leakage on facing
Replace the clutch disc, and inspect the transmis-
sion front oil seal, transmission case mating sur-
face, engine rear oil seal and other points for oil
leakage.
• 5MT EC, EK and KA model
• 5MT KS, K4 model and 6MT model
• 5MT turbo model
CL-00116
CL-00014
CL-00387
(A) Clutch facing
(A) Clutch facing
(A) Clutch facing
( A )
CL-00117
CL-00015
(A)
CL-00388
(A)
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