Subaru Outback (BR): General Description of Clutch System

A: SPECIFICATION

B: COMPONENT

1. CLUTCH ASSEMBLY

1. Dust cover
2. Lever spring
3. Pivot
4. Release lever (non-turbo model)
5. Clip (non-turbo model)
6. Release bearing (non-turbo model)
7. Release lever (turbo model)
8. Release bearing (turbo model)
9. Clutch cover
10. Clutch disc
11. Flexible flywheel

Tightening torque: N*m (kgf-m, ft-lb)
T1: 16 (1.6, 11.8)
T2: 75 (7.6, 55.3)

2. CLUTCH PIPE AND HOSE

1. Operating cylinder (turbo model)
2. Washer
3. Clutch hose (turbo model)
4. Operating cylinder (non-turbo model)
5. Clutch hose (non-turbo model)
6. Clutch hose bracket
7. Clamp
8. Clutch pipe
9. Connector
10. Reservoir tank bracket
11. Reservoir tank
12. Clutch pipe
13. Reservoir tank hose
14. Clutch pipe grommet
15. Clamp
16. Clutch pipe
17. Clamp
18. Clutch damper
19. Clutch pipe
20. Master cylinder ASSY
21. Mass damper

Tightening torque: N*m (kgf-m, ft-lb)
T1: 7.5 (0.8, 5.5)
T2: 7.8 (0.8, 5.8)
T3: 15 (1.5, 11.1)
T4: 18 (1.8, 13.3)
T5: 37 (3.8, 27.3)

3. MASTER CYLINDER

1. Master cylinder ASSY
2. Clevis pin
3. Clip

Tightening torque: N*m (kgf-m, ft-lb)
T: 18 (1.8, 13.3)

4. OPERATING CYLINDER

• Non-turbo model

1. Push rod
2. Boot
3. Piston
4. Piston spring
5. Operating cylinder
6. Breather screw

Tightening torque: N*m (kgf-m, ft-lb)
T: 7.8 (0.8, 5.8)

• Turbo model

1. Push rod
2. Boot
3. Piston
4. Piston spring
5. Operating cylinder
6. Breather screw

Tightening torque: N*m (kgf-m, ft-lb)
T: 7.8 (0.8, 5.8)

5. CLUTCH PEDAL ASSEMBLY

1. Clutch pedal
2. Clutch pedal pad
3. Brake pedal
4. Brake pedal pad
5. Stopper
6. Spacer
7. Bushing
8. Torsion spring
9. Assist bushing
10. Torsion spring bushing
11. Clevis pin
12. Snap pin
13. Bushing A
14. Assist spring (turbo model)
15. Clevis pin
16. Master cylinder ASSY
17. Clip
18. Clutch start switch
19. Stop & brake switch
20. Clutch switch
21. Pedal bracket
22. Sensor harness
23. Band

Tightening torque: N*m (kgf-m, ft-lb)
T1: 8 (0.8, 5.9)
T2: 18 (1.8, 13.3)
T3: 30 (3.1, 22.1)

C: CAUTION

• Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust and dirt.
• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
• Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
• Use SUBARU genuine fluid, grease etc. or equivalent. Do not mix fluid, grease, etc. of different grades or manufacturers.
• Be sure to tighten fasteners including bolts and nuts to the specified torque.
• Place shop jacks or rigid racks at the specified points.
• Apply grease onto sliding or revolving surfaces before installation.
• Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation.
• Before securing a part in a vise, place cushioning material such as wood blocks, aluminum plate or cloth between the part and the vise.
• Keep fluids away from the vehicle body. If any fluid contacts the vehicle body, immediately flush the area with water.

D: PREPARATION TOOL

1. SPECIAL TOOL

2. GENERAL TOOL

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