Subaru Outback manuals

Subaru Outback: Flywheel

A: REMOVAL

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

2) Remove the clutch cover and clutch disc. <Ref. to CL-11, REMOVAL, Clutch Disc and Cover.>

3) Using the ST, remove the flywheel.

ST 498497100 CRANKSHAFT STOPPER

Subaru Outback. Clutch System

  1. Flywheel

B: INSTALLATION

1) Temporarily tighten the flywheel, and attach the ST.

ST 498497100 CRANKSHAFT STOPPER

Subaru Outback. Clutch System

2) Tighten the flywheel mounting bolts to the specified torque.

NOTE: Tighten the flywheel attachment bolts gradually.

Each bolt should be tightened to the specified torque in crisscross order.

Tightening torque: 75 N*m (7.6 kgf-m, 55.3 ft-lb)

Subaru Outback. Clutch System

3) Install the clutch disc and cover. <Ref. to CL-11, INSTALLATION, Clutch Disc and Cover.>

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

C: INSPECTION

CAUTION: Because the center bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or solvents.

1) If there is damage or defectiveness in the facing sliding surface or ring gear, replace the flywheel.

Subaru Outback. Clutch System

  1. Flywheel
  2. Ring gear

2) Smoothness of rotation

Rotate the ball bearing while applying pressure in the thrust direction.

3) If noise or excessive play is noted, replace the flywheel.

Release Bearing and Lever

A: REMOVAL

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

2) Remove the two clips from the clutch release lever. (non-turbo model)

CAUTION: Be careful not to deform the clips.

3) Remove the release bearing. (non-turbo model)

4) Remove the dust cover.

Subaru Outback. Clutch System

  1. Release lever
  2. Dust cover

5) Remove the lever spring from the pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever. (non-turbo model)

Subaru Outback. Clutch System

  1. Release lever
  2. Screwdriver

6) Remove the lever spring from the pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever and release bearing as a unit. (turbo model)

Subaru Outback. Clutch System

  1. Release lever
  2. Screwdriver

B: INSTALLATION

NOTE: Apply the specified grease to lubricate to the following points before installation.

Grease
NICHIMOLY N-130 or equivalent

1) Temporarily assemble the release bearing to the release lever. (turbo model)

2) While pushing the release lever to the pivot and twisting it to both sides, fit the lever spring onto the raised portion of the pivot. (non-turbo model)

NOTE: Observing from the main case hole, check that the lever spring is installed securely.

3) Install the release bearing by inserting the release lever into the clutch housing release lever hole. Then, fit the lever spring onto the raised portion of the pivot by pushing the release lever to the pivot and twisting it to both sides. (turbo model)

4) Install the release bearing and fasten it with two clips. (non-turbo model)

5) Install the dust cover.

Subaru Outback. Clutch System

  1. Release lever
  2. Dust cover

6) Check the bearing for smooth movement by operating the release lever.

7) Apply grease to the contact point of the release lever and operating cylinder.

Grease
NICHIMOLY N-130 or equivalent

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

C: INSPECTION

1. RELEASE BEARING

CAUTION: Because this bearing is grease-sealed and is a non-lubrication type, do not wash with gasoline or solvents when servicing the clutch.

1) Check the bearing for smooth movement by applying force to the bearing in the radial direction.

Radial direction stroke: 1.6 mm (0.063 in)

Subaru Outback. Clutch System

  1. Bearing case

Subaru Outback. Clutch System

  1. Bearing case

2) While applying force to the bearing in the rotational direction, check the bearing for smooth rotation.

Subaru Outback. Clutch System

  1. Bearing case

Subaru Outback. Clutch System

  1. Bearing case

3) Check for wear or damage at the bearing case surface in contact with the lever.

2. RELEASE LEVER

Check the pivot portion of the lever and the contact area with the release bearing case for wear.

Subaru Outback. Clutch System

  1. Release lever
  2. Pivot
  3. Release bearing

Subaru Outback. Clutch System

  1. Release lever
  2. Pivot
  3. Release bearing

READ NEXT:

 Operating Cylinder

A: REMOVAL NOTE: The illustration below is suitable for every model. Perform the same procedures for the other models. 1) Remove the collector cover. (turbo model) 2) Remove the air intake boot ass

 Clutch Pipe and Hose

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the collector cover. (turbo model) 3) Remove the air intake boot assembly. (non-turbo model) <Ref. to IN(H4SO)-8, REMOVAL, Air Int

 Clutch Fluid

A: INSPECTION 1) Park the vehicle on a level surface. 2) Check the clutch fluid level using the scale on the outside of the reservoir tank. If the clutch fluid level is below "MIN", fill the clutch f

SEE MORE:

 Headlight Bulb

A: REMOVAL 1. HIGH BEAM CAUTION: Because the halogen bulb operates at a high temperature, dirt and oil on the bulb surface reduces the bulb's service life. Hold the flange portion when replacing the bulb. Never touch the glass portion. Do not leave the headlight without a bulb for a long tim

 Scalp Cap

A: REPLACEMENT 1. MODEL WITHOUT ELECTRIC RETRACTABLE MIRROR CAUTION: When removing the mirror, be careful not to damage the back surface of mirror with a flat tip screwdriver. When installing the mirror, insert the connector and clip securely. 1) Operate the remote control mirror switch to fac

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