M/T Clutch System: Clutch: Installation

Installation of clutch disc assembly
1. Center the clutch disc assembly with the SST.
  
  Fig 1: Installing Clutch Disc Assembly
  Courtesy of SUBARU OF AMERICA, INC.
  
  SST 499747100
  
  CAUTION: Be careful not to install the clutch disc assembly in the wrong direction.
Installation of clutch cover assembly
1. Match the alignment marks of the clutch cover assembly and the flywheel and install the clutch cover assembly.
  NOTE: When replacing the flywheel or the clutch cover with a new one, position the clutch cover so that the angle formed by the imbalance marks (paint marks) on the flywheel and clutch cover becomes 120 °or more. (The imbalance marks indicate the direction of residual imbalance.)
  
  Fig 2: Locating Alignment Marks, Imbalance Mark And Clutch Cover Assembly Bolt Tightening Sequence
  Courtesy of SUBARU OF AMERICA, INC.
2. Lightly tighten the bolts from the upper one near the flywheel knock pin and equally tighten the 6 bolts in the order shown in the figure after checking that the clutch disc assembly is positioned at the center by lightly shaking the SST from side to side and up and down.
  SST 499747100
  
  Standard value: T=16N.m {163kgf.cm} {11.8ft.lbf}
  
  CAUTION: Equally tighten the bolts in several times.
3. Remove the SST.
Installation of release fork support
1. Install the release fork support to the manual transmission assembly.
  Standard value: T=16N.m {163kgf.cm} {11.8ft.lbf}
Installation of clutch release fork boot
1. Install the clutch release fork boot to the manual transmission assembly.
Installation of release bearing hub clip.
1. Install 3 release bearing hub clips to the clutch release bearing assembly.
Installation of clutch release fork sub-assembly
1. Apply NICHIMOLY N-130 to the points of the clutch release fork sub-assembly shown in the figure.
  
  Fig 3: Locating Clutch Release Fork Sub-Assembly Grease Application Areas
  Courtesy of SUBARU OF AMERICA, INC.
  NOTE:
  - Contacting surface to release fork support
  - Contacting surface to release cylinder push rod
  - Contacting surface to release bearing hub
2. Install the clutch release fork sub-assembly to the clutch release bearing assembly.
Installation of clutch release bearing assembly
1. Apply NICHIMOLY N-130 to the input shaft spline area and inner periphery of the clutch release bearing assembly for the manual transmission assembly.
  
  Fig 4: Locating Input Shaft Spline Grease Application Area
  Courtesy of SUBARU OF AMERICA, INC.
  
  CAUTION: Do not apply NICHIMOLY N-130 to area A shown in the figure.
2. Install the clutch release bearing assembly and the clutch release fork sub-assembly to the manual transmission assembly.
  CAUTION: After installation, make sure the clutch release bearing assembly slides smoothly by moving the clutch release fork sub-assembly backward and forward.
Installation of manual transmission assembly (refer to INSTALLATION )