M/T Clutch System: Clutch: Installation

Installation of clutch disc ASSY
1. Center the clutch disc ASSY with the SST.
  
  Fig 1: Installing Clutch Disc Assy
  Courtesy of SUBARU OF AMERICA, INC.
  
  SST 499747100
  
  CAUTION: Be careful not to install the clutch disc ASSY in the wrong direction.
Installation of clutch cover ASSY
1. Match the alignment marks of the clutch cover ASSY and the flywheel and install the clutch cover ASSY.
  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: Flywheel Bolts 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 ASSY 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 ASSY.
  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 ASSY.
Installation of release bearing hub clip.
1. Install 3 release bearing hub clips to the clutch release bearing ASSY.
Installation of clutch release fork SUB-ASSY
1. Apply NICHIMOLY N-130 to the points of the clutch release fork SUB-ASSY shown in the figure.
  
  Fig 3: Locating Clutch Release Fork Sub-Assy Points
  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-ASSY to the clutch release bearing ASSY.
Installation of clutch release bearing ASSY
1. Apply NICHIMOLY N-130 to the input shaft spline area and inner periphery of the clutch release bearing ASSY for the manual transmission ASSY.
  
  Fig 4: Locating Clutch Release Bearing Assy With Input Shaft Spline 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 ASSY and the clutch release fork SUB-ASSY to the manual transmission ASSY.
  CAUTION: After installation, make sure the clutch release bearing ASSY slides smoothly by moving the clutch release fork SUB-ASSY backward and forward.
Fig 5: Installing Clutch Release Bearing Assy To Manual Transmission Assy
Courtesy of SUBARU OF AMERICA, INC.
Installation of manual transmission ASSY (refer to Installation )