High Clutch And Reverse Clutch

ST 498437000 HIGH CLUTCH PISTON GUIDE

Fig 4: Identifying Special Tool Attached To High Clutch Piston

Courtesy of SUBARU OF AMERICA, INC.

ST1 398673600 COMPRESSOR

ST2 498627100 SEAT

ST3 498437000 HIGH CLUTCH PISTON GUIDE

Fig 5: Installing Snap Ring Using Special Tools

Courtesy of SUBARU OF AMERICA, INC.

1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
2. Set the dial gauge to the clutch, and read its scale.
   NOTE: The value, which is read in the dial gauge at this time, is zero point.
3. Scale and record the weight "Z" of the flat board that will be placed on the retaining plate.
   NOTE:

   • Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
   • Use a flat board weighing less than 25.5 kg (56.2 lb).
4. Put the flat board on retaining plate.
   Fig 6: Putting Flat Board On Retaining Plate

   Courtesy of SUBARU OF AMERICA, INC.
5. Using the following formula, read the push/pull gauge, and calculate "N".

   N = 250 N (25.5 kgf, 56.2 lb) - Z

   N: Value indicated on push/pull gauge

   250 N (25.5 kgf, 56.2 lb) : Load applied to clutch plate

   Z: Flat board weight

6. Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record the compression amount "A". Measure at three or more locations spaced by equal distances and take the average value.
   NOTE: If measuring in three locations, measure every 120°. If measuring in four locations, measure every 90°.
   Fig 7: Measuring Compression Amount Using Gauge

   Courtesy of SUBARU OF AMERICA, INC.

1. Measure clearance "B" between the retaining plate and snap ring. (High clutch) At this time, do not press down the retaining plate.
   Fig 10: Measuring Clearance Between Retaining Plate And Snap Ring

   Courtesy of SUBARU OF AMERICA, INC.
2. Piston stroke calculation

   Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limits, replace the drive plate and select and adjust the retaining plate to be within initial standard values.

   T = A + B

   T: Piston stroke

   A: Amount of drive plate compression

   B: Clearance between retaining plate and snap ring

   Initial standard: 

   2.0 - 2.3 mm (0.079 - 0.091 in) 

   Limit thickness: 

   2.6 mm (0.102 in) 

Initial standard: 

0.8 - 1.1 mm (0.031 - 0.043 in) 

Limit thickness: 

1.5 mm (0.059 in) 

Fig 11: Measuring Clearance Between High Clutch Retaining Plate And Snap Ring (Turbo Model)

Courtesy of SUBARU OF AMERICA, INC.

If the clearance exceeds the service limits, replace the drive plate, then select and adjust the retaining plate so that the clearance is within default standard values.

1. Place the dish plate, driven plate, drive plate and retaining plate neatly in this order on surface table.
2. Set the dial gauge to the retaining plate, and read its scale.
   NOTE: The value, which is read in the dial gauge at this time, is zero point.
3. Scale and record the weight "Z" of the flat board that will be placed on the retaining plate.
   NOTE:

   • Use a stiff board which does not bend against load as a flat board to be put on retaining plate.
   • Use a flat board weighing less than 15.3 kg (33.7 lb).
4. Put the flat board on retaining plate.
   Fig 12: Putting Flat Board On Retaining Plate

   Courtesy of SUBARU OF AMERICA, INC.
5. Using the following formula, read the push/pull gauge, and calculate "N".

   N = 150 N (15.3 kgf, 33.7 lbf) - Z

   N: Value indicated on push/pull gauge

   150 N (15.3 kgf, 33.7 lbf): Load applied to the clutch plate

   Z: Flat board weight

6. Press the center of retaining plate with a force of N using a push/pull gauge, and measure and record the compression amount "A". Measure at three or more locations spaced by equal distances and take the average value.
   NOTE: If measuring in three locations, measure every 120°. If measuring in four locations, measure every 90°.
   Fig 13: Measuring Compression Amount Using Gauge

   Courtesy of SUBARU OF AMERICA, INC.
7. Install the driven plate, drive plate, retaining plate and snap ring.
   Fig 14: Installing Driven Plate, Drive Plate, Retaining Plate And Snap Ring

   Courtesy of SUBARU OF AMERICA, INC.
8. Apply compressed air intermittently to check for operation.
   Fig 15: Applying Compressed Air

   Courtesy of SUBARU OF AMERICA, INC.
9. Measure and record the clearance "B" between the retaining plate and snap ring. (Reverse clutch) At this time, do not press down the retaining plate.
   Fig 16: Measuring And Recording Clearance Between Retaining Plate And Snap Ring

   Courtesy of SUBARU OF AMERICA, INC.
10. Piston stroke calculation

    Calculate with A and B dimensions recorded before. If the calculated value exceeds the service limits, replace the drive plate and select and adjust the retaining plate to be within initial standard values.

    T = A + B

    T: Piston stroke

    A: Amount of drive plate compression

    B: Clearance between retaining plate and snap ring

    Initial standard: 

    1.1 - 1.4 mm (0.043 - 0.055 in) 

    Limit thickness: 

    1.6 mm (0.063 in)