Subaru Legacy III (2000-2003 year). Manual — part 636

MT-112

MANUAL TRANSMISSION AND DIFFERENTIAL

GENERAL DIAGNOSTIC

2. DIFFERENTIAL

Symptom

Possible cause

Remedy

1. Broken differential (case, gear, bear-
ing, etc.)
NOTE:
Abnormal noise will develop and finally it
will become impossible to continue to run
due to broken pieces obstructing the gear
revolution.

(a) Insufficient or improper oil

Disassemble differential and replace bro-
ken components and at the same time
check other components for any trouble,
and replace if necessary.

(b) Use of vehicle under severe condi-
tions such as excessive load and
improper use of clutch

Readjust bearing preload and backlash
and face contact of gears.

(c) Improper adjustment of taper roller
bearing

Adjust.

(d) Improper adjustment of drive pinion
and hypoid driven gear

Adjust.

(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion vehicle under severe operating
conditions.

Add recommended oil to specified level.
Do not use vehicle under severe operat-
ing conditions.

(f) Loose hypoid driven gear clamping
bolts

Tighten.

2. Differential and hypoid gear noises
Troubles of the differential and hypoid
gear always appear as noise problems.
Therefore noise is the first indication of
the trouble. However noises from the
engine, muffler, tire, exhaust gas, bear-
ing, body, etc. are easily mistaken for the
differential noise. Pay special attention to
the hypoid gear noise because it is easily
confused with other gear noises. There
are the following four kinds of noises.
• Gear noise when driving: If noise
increases as vehicle speed increases it
may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
• Gear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
• Bearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
• Noise which mainly occurs when turn-
ing: Unusual noise from differential side
gear, differential pinion, differential pin-
ion shaft, etc.

(a) Insufficient oil

Lubricate.

(b) Improper adjustment of hypoid driven
gear and drive pinion

Check tooth contact.

(c) Worn teeth of hypoid driven gear and
drive pinion

Replace as a set.
Readjust bearing preload.

(d) Loose roller bearing

Readjust hypoid driven gear to drive pin-
ion backlash and check tooth contact.

(e) Distorted hypoid driven gear or differ-
ential case

Replace.

(f) Worn washer and differential pinion
shaft

Replace.

CLUTCH SYSTEM

CL

Page

1.

General Description . . . . . . . . . . . . . . . . . . . . . 2

2.

Clutch Disc and Cover . . . . . . . . . . . . . . . . . . . ..15

3.

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.

Release Bearing and Lever. . . . . . . . . . . . . . . . . ...22

5.

Operating Cylinder . . . . . . . . . . . . . . . . . . . . . 25

6.

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . .27

7.

Clutch Pipe and Hose . . . . . . . . . . . . . . . . . . . ...29

8.

Clutch Fluid . . . . . . . . . . . . . . . . . . . . . . . ...30

9.

Clutch Fluid Air Bleeding. . . . . . . . . . . . . . . . . . ...31

10.

Clutch Pedal. . . . . . . . . . . . . . . . . . . . . . . ..33

11.

Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . 40

12.

General Diagnostic Table. . . . . . . . . . . . . . . . . . ..41

CL-2

CLUTCH SYSTEM

GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

Model

Europe and Australia

Except Europe and Austra-

lia

2.0 L Non-

Turbo

2.5 L

2.0 L Non-

Turbo

2.5 L

Clutch cover

Diaphragm set load

kgf (lb)

550 (1,213)

450 (992)

580 (1,279)

Clutch disc

Facing material

Woven

O.D.

×

I.D.

×

thickness

mm (in)

228.6

×

155

×

2.95

(9.00

×

6.10

×

0.1161)

225

×

150

×

3.5

(8.86

×

5.91

×

0.138)

Spline O.D.

mm (in)

25.2 (0.992)

Depth of rivet head mm (in)

Wear limit

0.3 (0.012)

Limit for deflection

mm (in)

1.0 (0.039) at R = 107 (4.21)

Clutch release lever ratio

1.6

Clutch pedal

Full stroke

mm (in)

130 — 135 (5.12 — 5.31)

Model

Australia

2.0 L Turbo

Clutch cover

Diaphragm set load

kgf (lb)

830 (1,830)

Clutch disc

Facing material

Woven

O.D.

×

I.D.

×

thickness

mm (in)

Flywheel side

230

×

150

×

3.2 (9.06

×

5.91

×

0.126)

Pressure plate side

230

×

150

×

3.5 (9.06

×

5.91

×

0.138)

Spline O.D.

mm (in)

25.2 (0.992)

Depth of rivet head mm (in)

Wear limit

0.3 (0.012)

Limit for deflection

mm (in)

0.8 (0.031) at R = 110 (4.33)

Clutch release lever ratio

1.7

Clutch pedal

Full stroke

mm (in)

130 — 135 (5.12 — 5.31)

CL-3

CLUTCH SYSTEM

GENERAL DESCRIPTION

B: COMPONENT

1. CLUTCH ASSEMBLY FOR EUROPE AND AUSTRALIA NON-TURBO MODELS

(1) Clutch release lever seal

(6) Release bearing

Tightening torque: N·m (kgf-m, ft-lb)

(2) Retainer spring

(7) Clutch cover

T1: 15.7 (1.6, 11.6)

(3) Pivot

(8) Clutch disc

T2: 72 (7.3, 52.8)

(4) Release lever

(9) Dual mass flywheel

(5) Clip

CL-00170

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 5 )

( 6 )

( 7 )

( 8 )

( 9 )

T1

T2

T1