Subaru Outback manuals

Subaru Outback: 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 assembly. (non-turbo model) <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Boot.>

3) Remove the intercooler. (turbo model) <Ref. to IN(H4DOTC)-17, REMOVAL, Intercooler.>

4) Disconnect the clutch hose from the operating cylinder.

CAUTION:

Subaru Outback. Clutch System

  1. Clutch hose
  2. Operating cylinder
  3. Cap bolt

5) Remove the operating cylinder from the transmission.

Subaru Outback. Clutch System

B: INSTALLATION

NOTE:

Grease
NICHIMOLY N-130 or equivalent

1) Install in the reverse order of removal.

Tightening torque:
T1: 18 N*m (1.8 kgf-m, 13.3 ft-lb)
T2: 37 N*m (3.8 kgf-m, 27.3 ft-lb)

Subaru Outback. Clutch System

  1. Clutch hose
  2. Operating cylinder
  3. Mark

2) After bleeding air from the operating cylinder, ensure that the clutch operates properly. <Ref. to CL-25, PROCEDURE, Clutch Fluid Air Bleeding.>

3) When the operating cylinder has been replaced or removed, 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: DISASSEMBLY

NOTE: The illustration shows a representing model. Perform the same procedures for the other models.

1) Remove the boot and push rod.

Subaru Outback. Clutch System

2) Apply compressed air through clutch hose attachment hole.

NOTE: Face the piston hole down and place a piece of wood underneath to prevent the piston from popping out.

3) Separate the piston and piston spring.

Subaru Outback. Clutch System

D: ASSEMBLY

NOTE:

Recommended clutch fluid: New FMVSS No. 116 DOT3

1) Install the piston spring onto the piston.

Subaru Outback. Clutch System

2) Insert piston to the operating cylinder.

3) Install push rod to the boot.

4) Install boot and push rod to the operating cylinder.

Subaru Outback. Clutch System

E: INSPECTION

1) Check that the operating cylinder is not damaged.

Replace the operating cylinder if it is damaged.

2) Check the clutch fluid leakage on the operating cylinder or the boot for damage. Replace the operating cylinder if clutch fluid leaks or boot damages are noted.

Master Cylinder

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the collector cover. (turbo model) 3) Thoroughly drain the clutch fluid from the reservoir tank.

4) Remove the instrument panel lower cover. <Ref. to EI-64, REMOVAL, Instrument Panel Lower Cover.>

5) Remove the pedal assembly. <Ref. to CL-26, REMOVAL, Clutch Pedal.>

6) Remove the clip and clevis pin, and then separate the push rod of the master cylinder from clutch pedal.

Subaru Outback. Clutch System

  1. Clevis pin
  2. Clip
  3. Push rod

7) Disconnect the clutch stroke sensor connector.

8) Remove the clutch pipe from the master cylinder.

Subaru Outback. Clutch System

9) Remove the master cylinder from the pedal bracket.

Subaru Outback. Clutch System

  1. Master cylinder

B: INSTALLATION

1) Install the master cylinder to the pedal assembly.

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

Subaru Outback. Clutch System

  1. Master cylinder

2) Connect the clutch pipes to the master cylinder.

Tightening torque: 15 N*m (1.5 kgf-m, 11.1 ft-lb)

Subaru Outback. Clutch System

3) Connect the clutch stroke sensor connector.

4) Connect the push rod of the master cylinder to the clutch pedal, and install the clevis pin and clip.

CAUTION: Always use a new clevis pin.

NOTE: Apply grease to the clevis pin.

Subaru Outback. Clutch System

  1. Clevis pin
  2. Clip
  3. Push rod

5) Install the pedal assembly. <Ref. to CL-26, INSTALLATION, Clutch Pedal.>

6) Install the instrument panel lower cover. <Ref. to EI-65, INSTALLATION, Instrument Panel Lower Cover.>

7) Connect the battery ground terminal.

8) Fill the recommended clutch fluid. <Ref. to CL- 24, Clutch Fluid.>

9) After bleeding air from the clutch system, ensure that the clutch operates properly. <Ref. to CL-25, Clutch Fluid Air Bleeding.>

10) Install the collector cover. (turbo model)

11) When the clutch master cylinder assembly 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

If any damage, deformation, wear, swelling, rust or other faults are found on the master cylinder assembly, reservoir tank, clutch damper, clutch pipe and clutch hose, replace the faulty part.

READ NEXT:

 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

 Clutch Pedal

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, INSTALLATION,

SEE MORE:

 Automatic Transmission Assembly

A: REMOVAL 1) Remove the front wheels. 2) Disconnect the ground cable from battery. 3) Remove the air intake duct. <Ref. to IN(H4SO)-9, REMOVAL, Air Intake Duct.> 4) Remove the air intake boot assembly. <Ref. to IN(H4SO)-8, REMOVAL, Air Intake Boot.> 5) Remove the ten clips and remo

 Rear Drive Shaft

A: REMOVAL 1) Remove the transmission assembly from the vehicle. <Ref. to 5AT-37, REMOVAL, Automatic Transmission Assembly.> 2) Remove the rear vehicle speed sensor, and then remove the extension case. <Ref. to 5AT-65, REMOVAL, Extension Case.> 3) Pull out the rear drive shaft from ce

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