Subaru Legacy III (2000-2003 year). Manual — part 646

CL-40

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 start
switch.

B: INSTALLATION

1) Install the clutch switch and clutch pedal stopper
so that the gap between them is 0 mm (0 in).

Tightening torque:

8 N·m (0.8 kgf-m, 5.8 ft-lb)

2) Measure stroke of clutch pedal.

Specified clutch pedal full stroke: A

130 — 135 mm (5.12 — 5.31 in)

3) If the clutch pedal stroke is out of specification,
adjust the stroke.<Ref. to CL-37, ADJUSTMENT,
Clutch Pedal.>
4) Connect clutch switch connector.

C: INSPECTION

1) Check the clutch switch continuity. If continuity is
not as specified, replace the switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between 1 and 2 of
switch terminal.
3) Check clutch switch continuity. If continuity is not
as specified, replace the switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between 1 and 2 of
switch terminal.

Terminals/Specified resistance

When clutch pedal depressed:

1 — 2/Less than 1

Ω

Terminals / Specified resistance

When clutch pedal not depressed:

1 — 2/More than 1 M

Ω

D: ADJUSTMENT

Refer to “ADJUSTMENT” for clutch pedal. <Ref. to
CL-37, ADJUSTMENT, Clutch Pedal.>

(A) Clutch switch

(B) Stopper

(A)

(B)

(C)

CL-00133

CL-00078

(A)

(B)

(C)

CL-00084

2 1

CL-41

CLUTCH SYSTEM

GENERAL DIAGNOSTIC TABLE

12.General Diagnostic Table

A: INSPECTION

1. CLUTCH

Symptom

Possible cause

Corrective

1. Clutch slippage.
It is hard to perceive clutch slippage in the early stage, but
pay attention to the following symptoms
• Engine speed up when shifting.
• High speed driving is impossible; especially rapid
acceleration impossible and vehicle speed does not
increase in proportion to an increase in engine speed.
• Power falls, particularly when ascending a slope, and
there is a smell of burning of the clutch facing.
• Method of testing: Put the vehicle in stationary condi-
tion with parking brake fully applied. Disengage the
clutch and shift the transmission gear into the first. Gradu-
ally 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 the vehicle
does not start off and the engine does not stall.

(a) Clutch facing smeared by oil

Replace.

(b) Worn clutch facing

Replace.

(d) Distorted pressure plate or fly-
wheel

Correct or replace.

(e) Defective release bearing
holder

Correct or replace.

2. Clutch drags.
As a symptom of this trouble, a harsh scratching noise
develops and control becomes quite difficult when shift-
ing gears. The symptom becomes more apparent when
shifting into the first gear. However, because much trou-
ble of this sort is due to defective synchronization mecha-
nism, carry out the test as described after.
• Method of testing: <Ref. to CL-42, DIAGNOSTIC DIA-
GRAM OF CLUTCH DRAG, INSPECTION, General Diag-
nostic Table.>
It may be judged as insufficient disengagement of clutch
if any noise occurs during this test.

(a) Worn or rusty clutch disc hub
spline

Replace clutch disc.

(b) Excessive deflection of clutch
disc facing

Correct or replace.

Replace.

(d) Cracked clutch disc facing

Replace.

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

Replace.

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

(a) Adhesion of oil on the facing

Replace clutch disc.

(b) Weak or broken torsion spring Replace clutch disc.

Replace clutch disc defection.

(d) Warped pressure plate or fly-
wheel

Correct or replace.

(e) Loose disc rivets

Replace clutch disc.

(f) Loose engine mounting

Retighten or replace mounting.

(g) Faulty pitching stopper

Replace.

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

(a) Broken, worn or unlubricated
release bearing

Replace release bearing.

(b) Insufficient lubrication of pilot
bearing

Apply grease.

Replace clutch disc.

(d) Loose torsion spring retainer

Replace clutch disc.

(e) Deteriorated or broken torsion
spring

Replace clutch disc.

CL-42

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 engages suddenly and the vehicle
jumps instead of making a smooth start.

(a) Grease or oil on facing

Replace clutch disc.

(b) Deteriorated cushioning
spring

Replace clutch disc.

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

(d) Deteriorated or broken torsion
spring

Replace clutch disc.

(e) Loose engine mounting

Retighten or replace mounting.

(f) Deteriorated diaphragm
spring

Replace.

Trouble

Corrective action

Insufficient pedal play

Adjust pedal play.

Clutch pedal free play insufficient

Adjust pedal free play.

Excessively worn and damaged pedal shaft and/or bushing

Replace bushing and/or shaft with new one.

Step

Value

Yes

CHECK GEAR NOISE.
1) Start the engine.
2) Disengage the clutch and shift quickly from

neutral to reverse in idling condition.

Is an abnormal noise heard
from the transmission gears?

Go to step 2.

Clutch is normal.

CHECK GEAR NOISE.
With the engine idling, disengage the clutch
and shift quickly (between 0.5 to 1.0 s) from
neutral to reverse.

Is an abnormal noise heard
from the transmission gears?

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.

CHECK GEAR NOISE.
With the engine idling, disengage the clutch
and shift quickly (between 0.5 to 1.0 s) from
neutral to reverse shift repeatedly between
neutral and reverse with clutch disengaged.

Is an abnormal noise heard
from the transmission gears?

Clutch is not dis-
engaged properly.
Inspect clutch
disc, clutch cover,
clutch release sys-
tem, and clutch
pedal free play.

Clutch disc and fly-
wheel are locked
together. Inspect
clutch disc and
clutch disc hub
spline.

Symptom

Possible cause

Corrective

FUJI HEAVY INDUSTRIES LTD.

G2300GE6

2003 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FRONT SUSPENSION

REAR SUSPENSION

WHEEL AND TIRE SYSTEM

DIFFERENTIALS

TRANSFER CASE

DRIVE SHAFT SYSTEM

ABS

ABS (DIAGNOSTICS)

ABS

VDC

VDC (DIAGNOSTICS)

VDC