Subaru Car 1998-05

Driven Disc & Pressure Plate 1

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Removal & Installation




CAUTION
The clutch driven disc may contain asbestos that has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch surface. When cleaning clutch surfaces, use a commercially available brake cleaning fluid.



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Fig. Exploded view of the clutch system components-mechanical clutch, non-turbo models



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Fig. Exploded view of the clutch system components-mechanical clutch, turbo models



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Fig. Exploded view of the clutch system components-hydraulic clutch

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle
     

  4.  
  5. Gradually unscrew the bolts which hold the pressure plate assembly on the flywheel. Loosen the bolts only 1 turn at a time, working around the pressure plate.
  6.  
  7. When all of the bolts have been removed, remove the clutch plate and disc.
  8.  


WARNING
Do not get oil or grease on the clutch facing.

  1. Remove the 2 retaining springs and remove the throwout bearing and the release fork.
  2.  


NOTE
Do not disassemble either the clutch cover or disc. Inspect the parts for wear or damage and replace any parts as necessary. Replace the clutch disc if there is any oil or grease on the facing. Do not wash or attempt to lubricate the throwout bearing. If it requires replacement, the bearing may be removed and a new one installed in the holder by means of a press.

To install:

  1. Fit the release fork boot on the front of the transaxle housing.
  2.  
  3. Install or connect the following:

    Release fork
     
    Throwout bearing assembly and secure it with the 2 springs. Coat the inside diameter of the bearing holder and the fork-to-holder contact points with grease.
     

  4.  
  5. Insert a pilot shaft through the clutch cover and disc, then insert the end of the pilot into the needle bearing.
  6.  
  7. If equipped, position theO
  8.  
  9. Tighten the pressure plate bolts gradually, 1 turn at a time, until the proper torque is reached. Tighten to 11 ft. lbs. (15 Nm).
  10.  


WARNING
When installing the clutch pressure plate assembly, be sure that the O marks on the flywheel and the clutch pressure plate assembly are at least 120 degrees apart. These marks indicate the direction of residual unbalance. Also, be sure that the clutch disc is installed properly, noting the FRONT and REAR markings.

  1. After installation of the transaxle in the car, perform the adjustments outlined above.
  2.  


CAUTION
The clutch driven disc may contain asbestos that has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch surface. When cleaning clutch surfaces, use a commercially available brake cleaning fluid.



Click image to see an enlarged view

Fig. Exploded view of the clutch system components-mechanical clutch



Click image to see an enlarged view

Fig. Exploded view of the clutch system components-hydraulic clutch

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transaxle
     

  4.  
  5. Gradually unscrew the six, 6mm bolts which hold the pressure plate assembly on the flywheel. Loosen the bolts only 1 turn at a time, working around the pressure plate.
  6.  
  7. When all of the bolts have been removed, remove the clutch plate and disc.
    WARNING
    Do not get oil or grease on the clutch facing.

  8.  
  9. Remove the 2 retaining springs and remove the throwout bearing and the release fork.
    NOTE
    Do not disassemble either the clutch cover or disc. Inspect the parts for wear or damage and replace any parts as necessary. Replace the clutch disc if there is any oil or grease on the facing. Do not wash or attempt to lubricate the throwout bearing. If it requires replacement, the bearing may be removed and a new one installed in the holder by means of a press.

  10.  

To install:

  1. Fit the release fork boot on the front of the transaxle housing.
  2.  
  3. Install or connect the following:

    Release fork
     
    Throwout bearing assembly and secure it with the 2 springs. Coat the inside diameter of the bearing holder and the fork-to-holder contact points with grease.
     

  4.  
  5. Insert a pilot shaft through the clutch cover and disc, then insert the end of the pilot into the needle bearing.
  6.  
  7. Tighten the pressure plate bolts gradually, 1 turn at a time, until the proper torque is reached. Tighten to 13 ft. lbs. (17 Nm).
    WARNING
    When installing the clutch pressure plate assembly, be sure that the O marks on the flywheel and the clutch pressure plate assembly are at least 120 degrees apart. These marks indicate the direction of residual unbalance. Also, be sure that the clutch disc is installed properly, noting the FRONT and REAR markings.

  8.  
  9. After installation of the transaxle in the car, perform the adjustments outlined above.
  10.  


CAUTION
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean clutch surfaces with compressed air! Avoid inhaling any dust from any clutch surface! When cleaning clutch surfaces, use a commercially available brake fluid.



Click image to see an enlarged view

Fig. Clutch system components-mechanical clutch-1997



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Fig. Clutch system components-hydraulic clutch-1997



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Fig. View of the clutch and pressure plate assembly-1997



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Fig. Loosen and remove the clutch and pressure plate bolts evenly, a little at a time . . .



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Fig. . . . then carefully removing the clutch and pressure plate assembly from the flywheel-1997



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Fig. The flywheel is accessible once the clutch assembly is removed-1997



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Fig. Check across the flywheel surface, it should be flat-1997



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Fig. If necessary, lock the flywheel in place and remove the retaining bolts . . .



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Fig. . . . then remove the flywheel from the crankshaft in order replace it or have it machined-1997



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Fig. Upon installation, it is usually a good idea to apply a threadlocking compound to the flywheel bolts-1997



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Fig. Check the pressure plate for excessive wear-1997



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Fig. Be sure that the flywheel surface is clean, before installing the clutch-1997



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Fig. Install a clutch alignment arbor, to align the clutch assembly during installation-1997



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Fig. Clutch plate installed with the arbor in place-1997



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Fig. Clutch plate and pressure plate installed with the alignment arbor in place-1997



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Fig. Pressure plate-to-flywheel bolt holes should align-1997



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Fig. You may want to use a threadlocking compound on the clutch assembly bolts-1997



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Fig. Install the clutch assembly bolts and tighten in steps, using an X pattern-1997



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Fig. Be sure to use a torque wrench to tighten all bolts-1997



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Fig. Grease the clutch release fork ball-1997



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Fig. Check the clutch release fork for signs of damage-1997



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Fig. Make sure the clutch release fork bearing clips are not bent or broken-1997



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Fig. Grease the throwout bearing assembly at the outer contact points-1997



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Fig. Grease the throwout bearing assembly at the inner contact points-1997

 
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