Subaru Legacy (2005 year). Manual — part 703

CL-31

CLUTCH SYSTEM

Clutch Pipe and Hose

7. Clutch Pipe and Hose

A: REMOVAL

1) Remove the air intake chamber. (Non turbo
model) <Ref. to IN(H4SO 2.0)-7, REMOVAL, Air In-
take Chamber.>
2) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
3) Drain the clutch fluid. <Ref. to CL-33, Clutch Flu-
id.>
4) Disconnect the clutch pipe from the clutch hose
and master cylinder.
5) Pull out the clamp, then remove the clutch hose
from bracket.

6) Disconnect the hose from operating cylinder.
7) Remove the bracket.

B: INSTALLATION

Install in the reverse order of removal.

NOTE:
Bleed air in the clutch fluid. <Ref. to CL-34, Clutch
Fluid Air Bleeding.>
• 5MT model

Tightening torque:

T1: 15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

T2: 18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

T3: 25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

(A) Clamp

(B) Clutch hose

CL-00057

(A)

(B)

(A) Clutch pipe (LHD model)

(B) Clip

(C) Clutch hose

(D) Clutch pipe (RHD model)

CL-00283

T1

T1

T1

T2

(A)

(B)

(B)

(C)

(C)

(C)

(D)

T1

T3

T3

CL-32

CLUTCH SYSTEM

Clutch Pipe and Hose

• 6MT model

Tightening torque:

T1: 15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

T2: 18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

T3: 25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

C: INSPECTION

Check the pipes and hoses for cracks, breakage or
damage. Check the joints for fluid leakage. If any
crack, breakage, damage or leakage is found, re-
pair or replace the defective pipe or hose.

(A) Clutch pipe (LHD model)

(B) Clip

(C) Clutch hose

(D) Clutch pipe (RHD model)

T3

T1

CL-00399

(D)

(A)

(B)

(B)

T1

T1

T3

(C)

T2

CL-33

CLUTCH SYSTEM

Clutch Fluid

8. Clutch Fluid

A: INSPECTION

1) Park the vehicle on a level surface.
2) Inspect the fluid level using the scale on the out-
side of reservoir tank. If the level is below “MIN”,
add fluid to bring it up to “MAX”, and then inspect
for leakage.

B: REPLACEMENT

CAUTION:
• The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
• When loosening the bleeder screw, cover the
bleeder with cloth to prevent brake fluid from
being splashed over surrounding parts.
• Avoid mixing different brands of brake fluid
to prevent the quality of fluid from degrading.
• Be careful not to allow dirt or dust to get into
the reservoir tank.

NOTE:
• During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to eliminate entry of
air.
• Clutch pedal operation must be very slow.
• Bleed air from the oil line with help of a co-work-
er.
• The necessary amount of brake fluid is approx.
70 m

2 (2.4 US fl oz, 2.5 Imp fl oz) for total clutch

system.
1) Remove the air intake chamber. <Ref. to
IN(H4SO 2.0)-7, REMOVAL, Air Intake Chamber.>
2) Drain the brake fluid from reservoir tank.
3) Refill the reservoir tank with recommended
brake fluid.

Recommended brake fluid:

FMVSS No. 116, fresh DOT3 or 4 brake fluid

4) Drain all the contaminated fluid in the same
method as air bleeding.

NOTE:
Keep the clutch reservoir tank filled with brake fluid
to eliminate entry of air.

(A) Reservoir tank

(B) MAX. level

(C) MIN. level

CL-00183

M

I

N

MA

X

(A)

(B)

(C)

CL-34

CLUTCH SYSTEM

Clutch Fluid Air Bleeding

9. Clutch Fluid Air Bleeding

A: PROCEDURE

1. 5MT MODEL

NOTE:
Bleed air from the oil line with help of a co-worker.
1) Remove the air intake chamber. <Ref. to
IN(H4SO 2.0)-7, REMOVAL, Air Intake Chamber.>
2) Remove the intercooler. <Ref. to IN(H4DOTC)-
12, REMOVAL, Intercooler.>
3) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and the other end into a brake
fluid container.

4) Slowly depress the clutch pedal and keep it de-
pressed. Open the air bleeder to discharge air to-
gether with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.

CAUTION:
Cover the bleeder with cloth to prevent brake
fluid from being splashed over surrounding
parts when loosening the bleeder.

5) Repeat the step 4) until there are no more air
bubbles in the vinyl tube.

6) Tighten the air bleeder.

Tightening torque:

T: 8 N

⋅

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

7) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire clutch
system.
8) After bleeding air from the clutch system, ensure
that clutch operates properly.

2. 6MT MODEL

NOTE:
Bleed air from the oil line with help of a co-worker.
1) Remove the air cleaner case. <Ref. to
IN(H6DO)-5, REMOVAL, Air Cleaner Case.>
2) Fit one end of a vinyl tube into the air bleeder of
master cylinder and the other end into a brake fluid
container.
3) Remove the operating cylinder.

NOTE:
Do not remove the clutch hose.

4) Fix the piston with clamp to avoid the piston from
jumping out.

(A) Clutch hose

(B) Air bleeder

(A) Operating cylinder

(B) Vinyl tube

CL-00259

(A)

(B)

CL-00260

(B)

(A)

CL-00261

T

CL-00068

CL-00069