Subaru Outback (BR): Clutch Disc and Cover

A: REMOVAL

1) Remove the transmission assembly from vehicle body. <Ref. to 6MT-25, REMOVAL, Manual Transmission Assembly.>

2) Attach the ST to the flywheel.

ST 499747100 CLUTCH DISC GUIDE

1. Clutch cover

3) Remove the clutch cover and clutch disc.

NOTE:

• Take care not to allow oil to touch the clutch disc face.
• Do not disassemble the clutch cover or clutch disc.

B: INSTALLATION

1) Insert the ST into the clutch disc and attach to the flywheel by inserting the ST end into pilot bearing.

NOTE: When installing the clutch disc, be careful to attach in the correct direction.

ST 499747100 CLUTCH DISC GUIDE

1. Flywheel side

2) Install the clutch cover to the flywheel and tighten the bolts to the specified torque.

NOTE:

• When installing a clutch cover to the flywheel, position the clutch cover so that the spacing between the unbalance marks (paint mark) on the flywheel and clutch cover is 120º or more apart. (The unbalance mark indicates the direction of residual unbalance.)
• Note the front and rear of the clutch disc when installing.
• Temporarily tighten the bolts by hand. Each bolt should be tightened to the specified torque in a crisscross order.

Tightening torque: 16 N*m (1.6 kgf-m, 11.8 ft-lb)

1. Unbalance mark (paint)

3) Remove the ST.

4) Install the transmission assembly. <Ref. to 6MT- 29, INSTALLATION, Manual Transmission Assembly.>

5) When the clutch disc has been replaced, perform the clutch sensor calibration mode. <Ref. to PB(diag)-20, CLUTCH SENSOR CALIBRATION MODE, OPERATION, Subaru Select Monitor.>

NOTE: If necessary, perform the clutch meet position setting.

<Ref. to PB(diag)-20, CLUTCH ENGAGEMENT POSITION SETTING, OPERATION, Subaru Select Monitor.>

C: INSPECTION

1. CLUTCH DISC

1) Facing wear

Measure the depth from the facing surface to the rivet head. Replace if the face is worn locally or worn down to less than the specified value.

Depth to rivet head: Limit of sinking 0.3 mm (0.012 in)

NOTE: Do not wash the clutch disc with any type of cleaning fluid.

2) Hardened facing

Replace the clutch disc.

3) Oil soakage on facing

Replace the clutch disc and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other locations for oil leakage.

1. Clutch facing

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

Limit for deflection: 0.7 mm (0.028 in) at R = 110 mm (4.33 in)

ST 499747100 CLUTCH DISC GUIDE

5) If there is spline wear, loose rivets, failed damper springs, etc., replace the clutch disc.

1. Spline
2. Rivet
3. Damper spring

2. CLUTCH COVER

NOTE: Visually check the following items without disassembling, and replace or repair if defective.

1) Loose thrust rivet

2) Damaged or worn bearing contact area at the center of diaphragm spring

1. Thrust rivet
2. Diaphragm spring

3) Damaged and worn disc contact surface of the pressure plate

4) Loose strap plate installation area

5) Worn sliding area of diaphragm spring

1. Pressure plate
2. Strap plate

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