Subaru Car 1998-05

Driven Disc & Pressure Plate 2

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Removal & Installation





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Fig. Installing the clutch release fork bearing clip-1997



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Fig. Be sure all parts move freely-1997

  1. Disconnect the negative battery cable. Remove the transaxle as outlined earlier in this section.
  2.  
  3. Gradually unscrew the six bolts (6mm) which hold the pressure plate assembly on the flywheel. Loosen the bolts only one turn at a time, working around the pressure plate. Do not unscrew all the bolts on one side at one time.
  4.  
  5. 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.

  6.  
  7. Remove the two 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.

  8.  

To install:

  1. Fit the release fork boot on the front of the transaxle housing. Install the release fork.
  2.  
  3. Insert the throwout bearing assembly and secure it with the two 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, one 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, make sure that the O marks on the flywheel and the clutch pressure plate assembly are at least 120° apart. These marks indicate the direction of residual unbalance. Also, make 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 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. Clutch and related components-1998-2004 mechanical clutch, non-turbocharged vehicles



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Fig. Clutch and related components-2002-2004 mechanical clutch, turbocharged vehicles



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Fig. Clutch and related components-1998-2004 hydraulic clutch

  1. Remove or disconnect the following:

    Negative battery cable
     
    Transmission
     

  2.  
  3. 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.
  4.  
  5. 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.

  6.  
  7. 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.

  8.  

To install:

  1. Fit the release fork boot on the front of the transmission 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 the O marks on the clutch cover and flywheel 120 degrees apart.
  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).
    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.

  10.  
  11. After installation of the transmission, perform the adjustments outlined above.
  12.  



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Fig. Clutch and related components-2005 non turbocharged vehicle



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Fig. Clutch and related components-2005 turbocharged vehicle



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Fig. Clutch and related components-2005 STI

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the transmission.
  4.  
  5. Install tool ST499747100, or equivalent on the flywheel.
  6.  
  7. Remove the clutch cover and clutch disc. Do not disassemble
    NOTE
    Be sure to put alignment marks on the flywheel and clutch cover before removing the clutch cover.

  8.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  

  1. Remove the transmission assembly. Refer to -Manual Transmission Assembly, Removal & Installation- in this section.
  2.  
  3. Remove the two clips from the clutch release lever and remove the clutch release bearing.
  4.  
  5. Remove the clutch release lever seal (dust cover).
  6.  
  7. Remove the clutch release lever retainer spring from the clutch release lever point with a screwdriver by accessing it through clutch housing clutch release lever hole.
  8.  
  9. Remove clutch release lever.

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    Fig. Exploded view of the clutch components



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    Fig. Remove the release lever retainer spring using a screwdriver-2001 Impreza shown, others similar

  10.  

To install:

  1. Before or during assembling, lubricate the following points with a light coat of grease.

    Inner groove of release bearing
     
    Contact surface of lever and pivot
     
    Contact surface of lever and bearing
     
    Transmission main shaft spline
     

  2.  
  3. While pushing the fork to pivot and twisting it to both sides, fit retainer spring onto the constricted portion of pivot.
    NOTE
    Apply grease to the contact point of release lever and slave cylinder.

  4.  
  5. Confirm that retainer spring is securely fitted by observing it through the main case hole.
  6.  
  7. Install the release bearing and fasten it with two clips.
  8.  
  9. Install the release lever seal.
  10.  
  11. Install the manual transmission assembly.
  12.  

 
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