Subaru Legacy IV (2008 year). Service manual — part 838

CL-38

Clutch Switch

CLUTCH SYSTEM

C: INSPECTION

1) Make sure that engine does not start with clutch
pedal not depressed. If the engine starts, adjust the
clutch switch and inspect the starter interlock cir-
cuit.
2) Make sure that the engine starts with the clutch
pedal fully depressed. If the engine does not start,
adjust the clutch switch and inspect the starter in-
terlock circuit.
3) Check the clutch switch for continuity. If the re-
sistance is not at the standard value, replace the
switch.

(1) Disconnect the clutch switch connector.
(2) Measure the resistance between terminal 1
and 2 of the switch.

Clutch switch (Clutch start)

Clutch switch (Cruise control)

D: ADJUSTMENT

1) Loosen the lock nut of clutch switch (clutch
start).

2) Fully depress the clutch pedal and hold it.
3) Adjust the gap of the clutch pedal plate and the
clutch switch to be 3.1 — 4.1 mm (0.12 — 0.16 in).

4) Tighten the lock nut.

Tightening torque:

8 N·m (0.8 kgf-m, 5.9 ft-lb)

Condition

Terminal No.

Specified resistance

When the clutch
pedal is depressed

1 and 2

Less than 1

:

Except when the
clutch the pedal is
depressed

1 and 2

1 M

: or more

CL-00102

1
2

CL-00084

2 1

(A) Lock nut

(B) Clutch switch (Clutch start)

(A) Plate

(B) Clutch switch (Clutch start)

(C) 3.1 — 4.1 mm (0.12 — 0.16 in)

(A)

(B)

CL-00537

(A)

(B)

(C)

CL-00104

CL-39

General Diagnostic Table

CLUTCH SYSTEM

12.General Diagnostic Table

A: INSPECTION

1. CLUTCH

Symptom

Possible cause

Corrective action

1. Clutch slippage.
It is hard to perceive clutch slippage in the early stage, but
pay attention to the following symptoms.
• Engine speeds up when shifting.
• High-speed driving is not possible; especially rapid
acceleration is not possible and vehicle speed does not
increase in proportion to the increase in engine speed.
• Power drops particularly when ascending a slope, and
there is a burning smell of the clutch plate.
• Method of testing: Park the vehicle and fully apply the
parking brake. Disengage the clutch and shift the transmis-
sion gear into the 1st. Gradually increase the engine speed
while gradually allowing the clutch to engage. The clutch
function is satisfactory if the engine stalls. However, the
clutch is slipping if the vehicle does not move forward and
the engine does not stall.

(a) Oil on the clutch face

Replace.

(b) Worn clutch face

Replace.

(c) Deteriorated diaphragm
spring

Replace.

(d) Warped pressure plate or fly-
wheel

Repair or replace.

(e) Defective release bearing
holder

Repair or replace.

2. Clutch drags.
As a symptom of this trouble, a harsh scratching noise
occurs and control becomes difficult when shifting gears.
The symptom becomes more apparent when shifting into
the 1st gear. However, because most trouble of this sort is
due to a defective synchronization mechanism, perform
the following tests.
Method of testing:<Ref. to CL-40, DIAGNOSTIC DIA-
GRAM OF CLUTCH DRAG, INSPECTION, General Diag-
nostic Table.>
The problem is caused by insufficient disengagement of
the clutch if an abnormal noise occurs during this test.

(a) Worn or rusty clutch disc hub
spline

Replace the clutch disc.

(b) Excessive deflection of clutch
disc face

Repair or replace.

(c) Crankshaft pilot needle bear-
ing sticking

Replace.

(d) Cracked clutch disc face

Replace.

(e) Stuck clutch disc (smeared
by oil or water)

Replace.

3. Clutch chatters.
Clutch chattering is an unpleasant vibration to the whole
vehicle when the vehicle is just started with clutch partially
engaged.

(a) Adhesion of oil on the clutch
face

Replace the clutch disc.

(b) Weak or broken damper
spring

Replace the clutch disc.

(c) Poor contact of the disc sur-
face or excessively worn disc

Replace the faulty clutch disc.

(d) Warped pressure plate or fly-
wheel

Repair or replace.

(e) Loose disc rivets

Replace the clutch disc.

(f) Loose engine mounting

Retighten or replace mounting.

(g) Improper adjustment of the
pitching stopper

Adjust.

4. Noisy clutch
Examine whether the noise is generated when the clutch is
disengaged, engaged, or partially engaged.

(a) Broken, worn or insufficiently
lubricated release bearing

Replace the release bearing.

(b) Insufficient lubrication of the
pilot bearing

Replace the pilot bearing.

(c) Loose clutch disc hub

Replace the clutch disc.

(d) Loose damper spring retainer Replace the clutch disc.

(e) Deteriorated or broken
damper spring

Replace the clutch disc.

CL-40

General Diagnostic Table

CLUTCH SYSTEM

2. CLUTCH PEDAL

3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

5. Clutch grabs suddenly.
When starting the vehicle with the clutch partially engaged,
the clutch engages suddenly and the vehicle jumps instead
of making a smooth start.

(a) Grease or oil on facing

Replace the clutch disc.

(b) Deteriorated cushioning
spring

Replace the clutch disc.

(c) Worn or rusted spline of
clutch disc or main shaft

Take off rust, apply grease or
replace clutch disc or main shaft.

(d) Deteriorated or broken
damper spring

Replace the clutch disc.

(e) Loose engine mounting

Retighten or replace mounting.

(f) Deteriorated diaphragm
spring

Replace.

Symptom

Corrective action

Insufficient pedal play

Adjust the free play of the pedal.

Insufficient clutch pedal free play

Adjust the free play of the pedal.

Excessively worn and damaged pedal shaft and/or bushing Replace the bushing or shaft with a new part.

Step

Check

Yes

No

1

CHECK GEAR NOISE.
1) Start the engine.
2) Disengage the clutch and shift quickly from
neutral to reverse in idling condition.

Is there any abnormal noise
from the transmission gear?

Go to step 2.

Clutch is normal.

2

CHECK GEAR NOISE.
Disengage the clutch at idle and shift from neu-
tral to reverse within 0.5 — 1.0 seconds.

Is there any abnormal noise
from the transmission gear?

Go to step 3.

Defective trans-
mission or exces-
sive clutch drag
torque. Inspect
pilot bearing,
clutch disc, trans-
mission and clutch
disc hub spline.

3

CHECK GEAR NOISE.
1) Disengage the clutch at idle and shift from
neutral to reverse within 0.5 — 1.0 seconds.
2) With the clutch disengaged, shift from neu-
tral to reverse, reverse to neutral several times.

Is there any abnormal noise
from the transmission gear?

Inadequate clutch
disengage. Inspect
the clutch disc,
clutch cover, clutch
release, and clutch
pedal free play.

Clutch and fly-
wheel seizure.
Inspect the clutch
disc and the spline
of the clutch disc
hub.

Symptom

Possible cause

Corrective action

FS-2

General Description

FRONT SUSPENSION

1. General Description

A: SPECIFICATION

*1

: OUTBACK model

–3 — 0 mm (–0.12 — 0 in) Toe angle (sum of both wheels): –0°15

c — 0°

*2

: Except for OUTBACK model

0

r3 mm (0r0.12 in) Toe angle (sum of both wheels): 0°r0°15c

NOTE:
• Front and rear toe-in and front camber can be
adjusted. Adjust if the toe-in or camber tolerance
exceeds specifications.
• Other items indicated in the specifications table
cannot be adjusted. If other items exceed specifica-
tions, check the suspension parts and connections
for deformation, and replace with new parts as re-
quired.

Model

Sedan

Wagon

2.5 i

2.5 GT spec.B,

3.0 R

2.5 GT spec.B,

3.0 R-LTD

2.5 i

2.5 GT

OUTBACK

Front

Wheel arch height
(Tolerance:

+12 mm

–24 mm

(

+0.47 in

–0.94 in

))

mm (in)

381 (15.0)

439 (17.3)

Camber (Tolerance:

r0°45c Differences

between RH and LH: 45

c or less)

–0°15

c

0°40

c

Caster (Referential Value)

5°55

c

5°40

c

4°55

c

Steering angle
(Tolerance:

r1.5°)

Inner
wheel

37.6°

33.8°

37.6°

Outer
wheel

33.0°

30.2°

33.0°

Toe-in

mm (in)

0

r3 (0r0.12) Toe angle (sum of both wheels): 0°r0°15c

Kingpin angle (Referential Value)

13°45

c

12°05

c

Rear

Wheel arch height
(Tolerance:

+12 mm

–24 mm

(

+0.47 in

–0.94 in

))

mm (in)

365 (14.4)

375 (14.8)

438 (17.2)

Camber (Tolerance:

r0°45c Differences

between RH and LH: 45

c or less)

–0°40

c

–0°30

c

–0°10

c

Toe-in

mm (in)

*2

*1

Thrust angle (Tolerance:

r0°30c)

0°

(1) Front

A – B = Positive: Toe-in, Negative: Toe-out
D = Individual toe angles

B

A

(1)

FS-00269