Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Driven Disc and Pressure Plate

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REMOVAL & INSTALLATION



See Figures 1 through 27


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.



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Fig. Fig. 1: Clutch system components-mechanical clutch



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Fig. Fig. 2: Clutch system components-hydraulic clutch



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Fig. Fig. 3: View of the clutch and pressure plate assembly



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Fig. Fig. 4: Removing the clutch and pressure plate bolts



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Fig. Fig. 5: Removing the clutch and pressure plate assembly



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Fig. Fig. 6: Removing the clutch and pressure plate



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Fig. Fig. 7: View of the flywheel once the clutch assembly is removed



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Fig. Fig. 8: Removing the flywheel bolts. Be sure to lock the flywheel in place



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Fig. Fig. 9: Removing the flywheel from the crankshaft



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Fig. Fig. 10: Add a thread locking agent to the flywheel bolts upon installation



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Fig. Fig. 11: Be sure that the flywheel surface is clean, before installing the clutch



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Fig. Fig. 12: Check across the flywheel surface, it should be flat



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Fig. Fig. 13: Checking the pressure plate for excessive wear



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Fig. Fig. 14: View of the clutch alignment arbor, used to install the clutch and pressure plate assembly



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Fig. Fig. 15: Install a clutch alignment arbor, to align the clutch assembly during installation



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Fig. Fig. 16: Clutch plate installed with the arbor in place



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Fig. Fig. 17: Pressure plate-to-flywheel bolt hole should align



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Fig. Fig. 18: Install locking agent to clutch assembly bolts



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Fig. Fig. 19: Be sure to use an torque wrench to tighten all bolts



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Fig. Fig. 20: Grease the clutch release fork ball



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Fig. Fig. 21: View of the clutch release fork, check this for signs of damage



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Fig. Fig. 22: View of the clutch release fork bearing clips, make sure these are not bent or broken



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Fig. Fig. 23: Removing the clutch release fork bearing clips



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Fig. Fig. 24: Grease the throwout bearing assembly at the outer contact points



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Fig. Fig. 25: Grease the throwout bearing assembly at the inner contact points



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Fig. Fig. 26: Installing the clutch release fork bearing clip



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Fig. Fig. 27: View of the clutch release fork assembly installed, be sure all parts move freely

  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.
  6.  


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

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

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. 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 12.7 ft. lbs. (17.2 Nm).
  8.  


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.

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

 
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