Subaru Legacy IV (2008 year). Manual - part 834

CL-22

Operating Cylinder

CLUTCH SYSTEM

5. Operating Cylinder

A: REMOVAL

1) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake
Chamber.>
2) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
3) Disconnect the clutch hose from the operating
cylinder.

CAUTION:
• Cover the hose joint to prevent the clutch flu-
id from flowing out.
• Do not loosen or remove the cap bolts.
• 5MT model

NOTE:
The illustration below is for a Non-turbo model.
However, perform the same procedures for the
Turbo model.

• 6MT model

4) Remove the operating cylinder from the trans-
mission.
• 5MT model

NOTE:
The illustration below is for a Non-turbo model.
However, perform the same procedures for the
Turbo model.

• 6MT model

(A) Clutch hose

(B) Operating cylinder

(A) Clutch hose

(B) Operating cylinder

(C) Cap bolt

CL-00367

(A)

(B)

CL-00420

(B)

(A)

(C)

(A) Operating cylinder

MT-01220

CL-00441

(A)

CL-23

Operating Cylinder

CLUTCH SYSTEM

B: INSTALLATION

1. 5MT MODEL

1) Install in the reverse order of removal.

NOTE:
• The illustration below is for a Non-turbo model.
However, perform the same procedures for the
Turbo model.
• Before installing the operating cylinder, apply
grease (KOPR-KOTE: Part No. 003603001) to the
contact point of the release lever and operating cyl-
inder.

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)

2) After bleeding air from the operating cylinder,
ensure that the clutch operates properly.
<Ref. to CL-30, Clutch Fluid Air Bleeding.>

2. 6MT MODEL

1) Install in the reverse order of removal.

NOTE:
Before installing the operating cylinder, apply
grease (KOPR-KOTE: Part No. 003603001) to the
contact point of the release lever and operating cyl-
inder.

Tightening torque:

T1: 18 N·m (1.8 kgf-m, 13.3 ft-lb)
T2: 41 N·m (4.2 kgf-m, 30.2 ft-lb)

NOTE:
• Be sure to install the clutch hose with the mark
side facing upward.
• Be careful not to twist the clutch hose during in-
stallation.

2) After bleeding air from the operating cylinder,
ensure that the clutch operates properly.
<Ref. to CL-30, Clutch Fluid Air Bleeding.>

CL-00368

T1

T2

T2

(A) Mark

(B) Clutch hose

(C) Operating cylinder

CL-00442

T2

T1

CL-00443

(A)

(B)

(C)

CL-24

Operating Cylinder

CLUTCH SYSTEM

C: DISASSEMBLY

1) Remove the boots and push rod assembly.

NOTE:
• Only 5MT model can be disassembled.
• The illustration below is for a Non-turbo model.

2) Apply compressed air through clutch hose at-
taching port.

NOTE:
Face the piston port down and place a piece of
wood underneath to prevent the piston from pop-
ping out.

3) Separate the piston and piston spring.

NOTE:
The illustration below is for a Non-turbo model.

D: ASSEMBLY

NOTE:
During assembly, apply hydraulic oil to all parts.

Recommended brake fluid

FMVSS No. 116, fresh DOT3 brake fluid

1) Install the piston spring onto the piston.

NOTE:
• Only 5MT model can be assembled.
• The illustration below is for a Non-turbo model.

2) Insert piston to the operating cylinder.
3) Install push rod to the boot.
4) Install boot and push rod to the operating cylin-
der.

NOTE:
The illustration below is for a Non-turbo model.

E: INSPECTION

1) Check the operating cylinder for damage. If op-
erating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on the boot. If any leakage or damage is
found, replace the operating cylinder.

CL-00457

CL-00458

CL-00459

CL-00459

CL-00457

CL-25

Master Cylinder

CLUTCH SYSTEM

6. Master Cylinder

A: REMOVAL

1) Thoroughly drain the brake fluid from the reser-
voir tank.
2) Remove the snap pin and clevis pin, and then
separate the push rod of the master cylinder from
clutch pedal.

3) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake
Chamber.>
4) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
5) Remove the clutch pipe from the master cylin-
der.
6) Remove the master cylinder and reservoir tank
as a unit.

CAUTION:
Be careful not to spill the brake fluid. Brake flu-
id spilled on the vehicle body will harm the
paint surface; if spilled, wash off with water im-
mediately and wipe off.

B: INSTALLATION

1) Install the master cylinder to the vehicle body,
and connect the clutch pipe to the master cylinder.

NOTE:
Check that the pipe is routed properly.

Tightening torque:

T1: 15 N·m (1.5 kgf-m, 11.1 ft-lb)
T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

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

NOTE:
Apply grease to the clevis pin.

3) After bleeding air from the clutch system, ensure
that the clutch operates properly. <Ref. to CL-30,
Clutch Fluid Air Bleeding.>
4) Install the air intake chamber. (Non-turbo model)
<Ref. to IN(H4SO)-7, INSTALLATION, Air Intake
Chamber.>
5) Install the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-13, INSTALLATION, Intercooler.>

(A) Clevis pin

(B) Snap pin

(C) Push rod

(D) Lock nut

(A) Master cylinder ASSY

(B) Clutch pipe

CL-00042

(A)

(B)

(C)

(D)

CL-00152

(A)

(B)

(A) Clevis pin

(B) Snap pin

(C) Push rod

CL-00561

T1

T2

CL-00045

(A)

(B)

(C)