Subaru Legacy IV (2008 year). Manual - part 835

CL-26

Master Cylinder

CLUTCH SYSTEM

C: DISASSEMBLY

1) Remove the straight pin and reservoir tank.

2) Remove the oil seal.

3) Move the seat towards the rear.

4) Remove the snap ring.

CAUTION:
When removing the piston stop ring, be careful
to prevent the rod, washer, piston and return
spring from coming out.
5) Remove the clutch damper.

D: ASSEMBLY

1) Install the clutch damper.

Tightening torque:

46.6 N·m (4.8 kgf-m, 34.4 ft-lb)

2) Apply a coat of grease to the contact surfaces of
the push rod and piston before installation.

Grease:

SILICONE GREASE G40M (Part No. 
004404003)

3) Assemble in the reverse order of disassembly.

Tightening torque:

10 N·m (1.0 kgf-m, 7.4 ft-lb)

E: INSPECTION

If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, clutch
damper, seat or hose, replace the faulty part.

(A) Reservoir tank

(B) Straight pin

(A) Oil seal

(B) Master cylinder

(A) Seat

(B) Master cylinder

CL-00562

(A)

(B)

CL-00612

(A)

(B)

CL-00513

(A)

(B)

(A) Master cylinder body

(B) Return spring

(C) Piston

(D) Stop ring

(E) Push rod ASSY

(F) Clutch damper

(G) Seat

CL-00564

CL-00565

(B)

(C)

(D)

(E)

(A)

(F)

(G)

CL-27

Clutch Pipe and Hose

CLUTCH SYSTEM

7. Clutch Pipe and Hose

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) Drain the clutch fluid. <Ref. to CL-29, Clutch Flu-
id.>
4) Disconnect the clutch pipe from the clutch hose
and master cylinder.
5) Pull out the clamp, then remove the clutch hose
from the bracket.

6) Disconnect the hose from the operating cylinder.
7) Remove the bracket.

B: INSTALLATION

Install in the reverse order of removal.

NOTE:
Bleed air from the clutch fluid. <Ref. to CL-30,
Clutch Fluid Air Bleeding.>
• 5MT model

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)
T3: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

(A) Clamp

(B) Clutch hose

CL-00057

(A)

(B)

(A) Clutch pipe

(B) Clip

(C) Clutch hose (Non-turbo model)

(D) Operating cylinder (Non-turbo model)

(E) Operating cylinder (Turbo model)

(F) Clutch hose (Turbo model)

T1

T2

(A)

(B)

(C)

(D)

(E)

(C)

T1

T3

T2

(F)

CL-00651

CL-28

Clutch Pipe and Hose

CLUTCH SYSTEM

• 6MT model

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)
T3: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

C: INSPECTION

Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, re-
pair or replace the defective pipe or hose.

(A) Clutch pipe

(B) Clip

(C) Clutch hose

(D) Operating cylinder (6MT turbo model)

CL-00652

T1

(A)

(B)

(C)

T1

T3

(C)

T2

(D)

CL-29

Clutch Fluid

CLUTCH SYSTEM

8. Clutch Fluid

A: INSPECTION

1) Park the vehicle on a level surface.
2) Inspect the fluid level using the scale on the out-
side of the reservoir tank. If the level is below “MIN”,
add fluid to bring it up to “MAX”, and also inspect for
leakage.

B: REPLACEMENT

CAUTION:
• Use fresh FMVSS No. 116, DOT3 brake fluid.
• Cover the bleeder with cloth to prevent brake
fluid from being splashed on surrounding parts
when loosening the bleeder.
• Avoid mixing brake fluid of different brands
to prevent fluid performance from degrading.
• Be careful not to allow dirt or dust to enter the
reservoir tank.

NOTE:
• During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to prevent entry of
air.
• Clutch pedal must be operated very slowly.
• For convenience and safety, it is advisable to
have two people working.
• The amount of brake fluid required is approxi-
mately 70 m

2 (2.4 US fl oz, 2.5 Imp fl oz) for total

clutch system.
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) Drain the brake fluid from the reservoir tank.
4) Refill the reservoir tank with recommended
brake fluid.

Recommended brake fluid:

FMVSS No. 116, fresh DOT3 brake fluid

5) If necessary, bleed air from the clutch fluid. <Ref.
to CL-30, Clutch Fluid Air Bleeding.>

(A) Reservoir tank

(B) MAX. level

(C) MIN. level

CL-00183

M I N

MAX

(A)

(B)

(C)