Clutch Disc: Service and Repair

The content of this article/image reflects the changes identified in tsb 18_99_06 Dated 01/19/06 and applies to Legacy, Forester, Impreza and Baja models.

Clutch Disc and Cover

REMOVAL
1. Remove the transmission assembly from vehicle body.





2. Install the ST on flywheel.
ST 499747100 CRANKSHAFT STOPPER
3. Remove the clutch cover and clutch disc.

NOTE:
^ Take care not to allow oil on the clutch disc facing.
^ Do not disassemble either the clutch cover or clutch disc.

INSTALLATION

1. Insert the ST into clutch disc and install them on the flywheel by inserting the ST end into pilot bearing.

NOTE:
When installing the clutch disc, be careful to its direction.





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 installing.

^ Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross order.





Tightening torque: 16 N.m (1.6 kg f-rn, 11.8 ft.lbs.)

3. Remove the ST.
4. Install the transmission assembly.

INSPECTION
CLUTCH DISC
1. Facing wear Measure the depth of rivet head from the surface of facing. Replace if 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 inch)





NOTE: Do not wash the clutch disc with any cleaning fluid.

2. Hardened facing Correct by using emery paper or replace.





3. Oil soakage on facing Replace the clutch disc (A) and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage.





4. Deflection on facing If deflection exceeds the specified value at the outer circumference of facing, repair or replace.
ST 499747100 CLUTCH DISC GUIDE
Limit for deflection: 0.8 mm (0.031 inch) at R = 107 mm (4.21 inch)





5. Worn spline, loose rivets and torsion spring failure Replace defective parts.

CLUTCH COVER

NOTE: Visually check for the following items without disassembling, and replace or repair if defective.

1. Loose thrust rivet.





2. Damaged or worn bearing contact area at center of diaphragm spring.