Manual transmissions use a clutch to engage and disengage the power from the engine to the transmission. This is necessary so that when you are at a complete stop, you can rest at idle without the motor stalling out. The clutch disc is sandwiched between the engine flywheel and the transmission pressure plate. When you switch gears and let off the clutch pedal, there is a short period in which the clutch is slipping to transmit the power in a controlled way. This slipping causes the clutch to wear over time and require replacement. Replacing the clutch in your Subaru is straightforward and is similar to replacing a clutch in any vehicle with some minor differences.
- Skill level:
- Moderately Challenging
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Things you need
- New clutch kit
- Resurfaced or new flywheel
- Jack stands
- Transmission lift attachment for jack stand
Jack the vehicle and place on jack stands.
Drain the transmission gear oil so that it doesn't leak when you are removing the transmission.
Disconnect the driveshaft and exhaust pipe, as they will both be in the way of removing the transmission.
Remove the transmission mount at the top the transmission. It will be connected to the firewall and held with a bolt.
Disconnect any wiring connected to the transmission and remember where they go.
Disconnect both drive axles from the transmission. Subaru uses pins that hold the axles to the transmission. Use a punch and hammer to drive the pins out to remove the axles.
Remove the bolts holding the transmission to the engine block (there will be approximately seven or eight bolts). Place a transmission lift underneath the transmission to hold the transmission and lower it down. If you don't have a transmission lift, you can also use a transmission attachment for your jack.
Shake the transmission back and forth until it drops onto the jack. Pull the transmission straight back, ensuring that no pressure is put on the input shaft, and lower the transmission to the ground.
Remove the pressure plate and clutch disc from the flywheel with a ratchet. Then remove the flywheel with a ratchet and replace with a new flywheel or have your flywheel professionally machined at a machine shop. Torque the flywheel down to the manufacturer specification.
Place the clutch disc on the clutch disc alignment tool and insert the tool in the flywheel input shaft hole. Connect the new pressure plate to the flywheel and torque the bolts. Once the pressure plate is torqued down, remove the clutch alignment tool.
Grease the new throw-out bearing and place it on the input shaft of the transmission. Once the transmission is installed, it will push against the pressure plate.
Jack the transmission back into place and push the input shaft straight into the flywheel hole and push the transmission into place and bolt it down to specification.
Install the axles and insert new pins.
Reconnect the wiring, exhaust system, and driveshaft.
Connect the transmission to the transmission mount connected to the firewall.
Tips and warnings
- Removing the flywheel may prove difficult because as you turn the bolts on the flywheel, it turns. To stop it from turning, have a helper hold the crank bolt with a ratchet and large socket while you loosen the flywheel bolts.
- The transmission is very heavy (68kg.) and could inflict injury if you are not careful handing the transmission. If you aren't in good shape physically, this job is better left to the pros.
- Wear safety goggles to protect yourself from injury.
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