Subaru Forester 1998-05

Driven Disc & Pressure Plate

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Removal & Installation




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 cleaning fluid.

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

    Negative battery cable
     
    Transmission
     

  4.  


WARNING
Removing the bolts on one side of the pressure plate will warp the pressure plate, rendering it useless.

  1. Gradually unscrew the six 6mm bolts that hold the pressure plate assembly on the flywheel. Loosen the bolts only 1 turn at a time, working around the pressure plate. Do not unscrew all the bolts on one side at one time.
  2.  
  3. Remove or disconnect the following:

    Clutch plate and disc
     
    2 retaining springs, the throwout bearing and the release fork
     

  4.  


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, because it is sealed and permanently lubricated. 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 transmission housing.
  2.  
  3. Install or connect the following:

    Release fork
     
    Throwout bearing assembly and secure it with the 2 springs
     

  4.  


NOTE
Coat the inside diameter of the throwout bearing and the release lever contact points with grease.



Clutch alignment tool through the clutch cover and disc, then insert the end of the tool into the needle bearing
 



Click image to see an enlarged view

Fig. Clutch cover alignment and tightening sequence

  1. Tighten the pressure plate bolts following the illustrated sequence, 1 turn at a time, until the proper torque is reached. Tighten to 12 ft. lbs. (16 Nm).
  2.  


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. Install the transmission.
  2.  


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 cleaning fluid.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    Removing the bolts on one side of the pressure plate will warp the pressure plate, rendering it useless.



    Negative battery cable
     
    Transmission
     

  4.  
  5. Gradually unscrew the six 6mm bolts that hold the pressure plate assembly on the flywheel. Loosen the bolts only 1 turn at a time, working around the pressure plate. Do not unscrew all the bolts on one side at one time.
  6.  
  7. Remove or disconnect the following:
    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, because it is sealed and permanently lubricated. If it requires replacement, the bearing may be removed and a new one installed in the holder by means of a press.



    Clutch plate and disc
     
    2 retaining springs, the throwout bearing and the release fork
     

  8.  

To install:

  1. Fit the release fork boot on the front of the transmission housing.
  2.  
  3. Install or connect the following:
    NOTE
    Coat the inside diameter of the throwout bearing and the release lever contact points with grease.



    Release fork
     
    Throwout bearing assembly and secure it with the 2 springs
     



    Clutch alignment tool through the clutch cover and disc, then insert the end of the tool into the needle bearing

    Click image to see an enlarged view

    Fig. Clutch cover alignment and tightening sequence

     

  4.  
  5. Tighten the pressure plate bolts following the illustrated sequence, 1 turn at a time, until the proper torque is reached. Tighten to 12 ft. lbs. (16 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.

  6.  
  7. Install the transmission.
  8.  

Non-Turbo Models
  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.

    Click image to see an enlarged view

    Fig. Remove the release lever retainer spring using a screwdriver

  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.  

Turbo Models
  1. Remove the transmission assembly. Refer to -Manual Transmission Assembly, Removal & Installation- in this section.
  2.  
  3. Remove the clutch release lever from the transmission.
  4.  
  5. Put the clutch release bearing in the engine side.
  6.  
  7. Remove the clutch release bearing from the clutch cover using a flat tip screwdriver.

    Click image to see an enlarged view

    Fig. Remove the clutch release bearing using a screwdriver-Turbo Models

  8.  

To install:

  1. Install the release bearing on the transmission.
  2.  
  3. Insert the release fork into the release bearing tab.
    NOTE
    Apply grease to the contact point of release lever and slave cylinder.

  4.  
  5. Insert the release fork shaft into the release fork.
  6.  
  7. Tighten the plug.
  8.  
  9. Move the release fork to ensure that the release bearing and release fork move slowly.
  10.  
  11. Install the manual transmission assembly.
  12.  

 
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