Subaru Legacy (2005 year). Service manual — part 706

CL-43

CLUTCH SYSTEM

Clutch Switch

11.Clutch Switch

A: REMOVAL

1) Disconnect the ground cable from battery.
2) Remove the instrument panel lower cover.
3) Disconnect the connector from clutch switch.
4) Remove the clutch switch.

B: INSTALLATION

1) Install the clutch switch so that the clearance
from the clutch pedal stopper is 0 mm (0 in).

Tightening torque:

8 N

⋅

m (0.8 kgf-m, 5.8 ft-lb)

2) Measure the stroke of clutch pedal.

Specified clutch pedal full stroke A:

Non-turbo model

130 — 135 mm (5.12 — 5.31 in)

Turbo model

135 — 140 mm (5.31 — 5.51 in)

3) If the clutch pedal stroke is out of specification,
adjust the stroke. <Ref. to CL-39, ADJUSTMENT,
Clutch Pedal.>
4) Connect the clutch switch connector.

C: INSPECTION

Check the clutch switch continuity. If the continuity
is not as specified, replace the switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between switch termi-
nal 1 and 2.

D: ADJUSTMENT

Refer to “ADJUSTMENT” for clutch pedal. <Ref. to
CL-39, ADJUSTMENT, Clutch Pedal.>

(A) Clutch switch

(B) Stopper

(C) 0 mm (0 in)

(A) Clutch pedal (at full stroke condition)

(B) Scale

(C) Seat

CL-00133

(A)

(B)

(C)

CL-00078

(A)

(B)

(C)

A

Condition

Terminal No.

Specified resis-

tance

When clutch pedal
depressed

No. 1 — No. 2

More than 1

M

Ω

When clutch pedal
released

No. 1 — No. 2

Less than 1

Ω

CL-00084

2 1

CL-44

CLUTCH SYSTEM

General Diagnostic Table

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 impossible; espe-
cially rapid acceleration is impossible and
vehicle speed does not increase in pro-
portion to the increase in engine speed.
• Power falls, particularly when ascend-
ing a slope, and there is a smell of burn-
ing of the clutch facing.
• Method of testing: Put the vehicle in a
stationary condition with parking brake
fully applied. Disengage the clutch and
shift the transmission gear into the
1st.Gradually allow the clutch to engage
while gradually increasing the engine
speed. The clutch function is satisfactory
if the engine stalls. However, the clutch is
slipping if neither the vehicle starts off nor
the engine stalls.

(a) Clutch facing smeared with oil

Replace.

(b) Worn clutch facing

Replace.

(c) Deteriorated diaphragm spring

Replace.

(d) Distorted pressure plate or flywheel

Rectify or replace.

(e) Defective release bearing holder

Rectify or replace.

2. Clutch drags.
As a symptom of this trouble, a harsh
scratching noise develops and control
becomes quite difficult when shifting
gears. The symptom becomes more
apparent when shifting into the 1st gear.
However, because much trouble of this
sort is due to defective synchronization
mechanism, carry out the following tests.
• Method of testing: <Ref. to CL-45,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnos-
tic Table.>
It may be judged as insufficient disen-
gagement of clutch if any noise occurs
during this test.

(a) Worn or rusty clutch disc hub spline

Replace the clutch disc.

(b) Excessive deflection of clutch disc
facing

Rectify or replace.

(c) Stuck crankshaft pilot needle bearing

Replace.

(d) Cracked clutch disc facing

Replace.

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

Replace.

3. Clutch chatters.
Clutch chattering is an unpleasant vibra-
tion to the whole body when the vehicle is
just started with clutch partially engaged.

(a) Facing smeared with oil

Replace the clutch disc.

(b) Weak or broken damper spring

Replace the clutch disc.

(c) Defective facing contact or exces-
sively worn disc

Replace the defective clutch disc.

(d) Warped pressure plate or flywheel

Rectify or replace.

(e) Loose disc rivets

Replace the clutch disc.

(f) Loose engine mounting

Retighten or replace mounting.

(g) Improper adjustment of pitching stop-
per

Adjust.

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

(a) Broken, worn or insufficient lubrication
of release bearing

Replace the release bearing.

(b) Insufficient lubrication of 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-45

CLUTCH SYSTEM

General Diagnostic Table

2. CLUTCH PEDAL

3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

5. Clutch grabs.
When starting the vehicle with the clutch
partially engaged, the clutch grabs sud-
denly 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 and 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.

Trouble

Corrective action

Insufficient pedal play

Adjust pedal free play.

Insufficient clutch pedal free play

Adjust pedal free play.

Excessively worn and damaged pedal shaft or bushing

Replace the bushing or shaft with a new one.

Step

Check

Yes

No

1

CHECK GEAR NOISE.
1) Start the engine.
2) Depress the clutch pedal at idle and quickly
shift from neutral to reverse.

Is there any noise from the
transmission gear?

Go to step 2.

Clutch is normal.

2

CHECK GEAR NOISE.
Depress the clutch pedal at idle and shift from
neutral to reverse within 0.5 — 1.0 seconds.

Is there any 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 pedal depressed, shift from
neutral to reverse, reverse to neutral several
times.

Is there any noise from the
transmission gear?

Defect in clutch
disengaging.
Inspect the clutch
disc, clutch cover,
clutch release and
clutch pedal free
play.

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

Symptom

Possible cause

Corrective action

CL-46

CLUTCH SYSTEM

General Diagnostic Table