Subaru Legacy (2005 year). Service manual — part 700

CL-19

CLUTCH SYSTEM

Clutch Disc and Cover

4) Deflection on facing
If the deflection at the outer circumference of facing
exceeds the specified value, replace the clutch
disc.
ST

499747100

CLUTCH DISC GUIDE

Limit for deflection:

1.0 mm (0.039 in) at R = 110 mm (4.33 in)

• 5MT EC, EK and KA model

• 5MT KS, K4, turbo model and 6MT model

5) If there is worn spline, loose rivet or faulty damp-
er spring, replace the clutch disc.
• 5MT EC, EK and KA model

• 5MT KS, K4 model and 6MT model

• 5MT turbo model

2. CLUTCH COVER

NOTE:
Visually check the following items without disas-
sembling, and replace or repair if defective.
1) Loose thrust rivet
2) Damaged or worn bearing contact area at the
center of diaphragm spring
• 5MT EC, EK and KA model

(A) Spline

(B) Rivet

ST

CL-00118

CL-00016

S T

( A )

( B )

CL-00119

(A) Spline

(B) Rivet

(C) Damper spring

(A) Spline

(B) Rivet

(C) Damper spring

(A) Thrust rivet

(B) Diaphragm spring

CL-00017

CL-00389

(B)

(A)

(C)

( A )

( B )

CL-00120

CL-20

CLUTCH SYSTEM

Clutch Disc and Cover

• 5MT KS, K4, turbo model and 6MT model

3) Damage or wear of disc contact surface on pres-
sure plate
4) Loose strap plate installation area
5) Wear of diaphragm sliding area
• 5MT EC, EK and KA model

• 5MT KS, K4, turbo model and 6MT model

(A) Thrust rivet

(B) Diaphragm spring

(A) Pressure plate

(B) Strap plate

(A) Pressure plate

(B) Strap plate

CL-00018

( A )

( B )

CL-00176

(A)

(B)

CL-00177

(A)

(B)

CL-21

CLUTCH SYSTEM

Flywheel

3. Flywheel

A: REMOVAL

1. 5MT EC, EK AND KA MODEL

1) Remove the transmission assembly. <Ref. to
5MT-30, REMOVAL, Manual Transmission As-
sembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-16, REMOVAL, Clutch Disc and Cover.>
3) Using the ST1 and ST2, remove the flywheel.
ST1

498497100

CRANKSHAFT STOPPER

ST2

499057000

TORX PLUS

®

2. 5MT KS, K4 MODEL AND 6MT MODEL

1) Remove the transmission assembly. <Ref. to
5MT-30, REMOVAL, Manual Transmission As-
sembly.> <Ref. to 6MT-36, INSTALLATION, Man-
ual Transmission Assembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-16, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST

498497100

CRANKSHAFT STOPPER

B: INSTALLATION

1. 5MT EC, EK AND KA MODEL

1) Install the flywheel and ST.
ST

498497100

CRANKSHAFT STOPPER

2) Tighten the flywheel attaching bolts to the spec-
ified torque.
ST

499057000

TORX PLUS

®

NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross order.

Tightening torque:

72 N

⋅

m (7.3 kgf-m, 52.8 ft-lb)

3) Install the clutch disc and cover. <Ref. to CL-16,
INSTALLATION, Clutch Disc and Cover.>
4) Install the transmission assembly. <Ref. to 5MT-
32, INSTALLATION, Manual Transmission Assem-
bly.>

(A) Flywheel

(A) Flywheel

ST1

ST2

( A )

CL-00121

CL-00019

S T

( A )

ST

CL-00122

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

CL-00123

CL-22

CLUTCH SYSTEM

Flywheel

2. 5MT KS, K4 MODEL AND 6MT MODEL

1) Install the flywheel and ST.
ST

498497100

CRANKSHAFT STOPPER

2) Tighten the flywheel attaching bolts to the spec-
ified torque.

NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross order.

Tightening torque:

5MT model

72 N

⋅

m (7.3 kgf-m, 52.8 ft-lb)

6MT model

81 N

⋅

m (8.2 kgf-m, 59.4 ft-lb)

3) Install the clutch disc and cover. <Ref. to CL-17,
5MT KS, K4, TURBO MODEL AND 6MT MODEL,
INSTALLATION, Clutch Disc and Cover.>
4) Install the transmission assembly. <Ref. to 5MT-
32, INSTALLATION, Manual Transmission Assem-
bly.> <Ref. to 6MT-36, INSTALLATION, Manual
Transmission Assembly.>

C: INSPECTION

CAUTION:
Since this bearing is grease-sealed and non-lu-
brication type, do not wash it with gasoline or
any other solvent.
1) Damage on facing sliding surface and ring gear
If defective, replace the flywheel.
• 5MT EC, EK and KA model

• 5MT KS, K4 model and 6MT model

2) Smoothness of rotation
Rotate the ball bearing while applying pressure in
thrust direction.
3) If noise or excessive play is noted, replace the
flywheel.

CL-00020

S T

CL-00021

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

(A) Flywheel

(B) Ring gear

(A) Flywheel

(B) Ring gear

( A )

( B )

CL-00124

CL-00022

( B )

( A )