Hey Guys,
I'm doing my first full clutch replacement over the next few days and weekend, Ive got an Exedy here that I picked up today, Got it at a great price from npcperformance.com.au (great bunch there) and I now need to put it in. (I didn't stall my car in 4th today taking off.)
Just a few things, I've never done an AWD or one with Dual Range so this is going to be really interesting.
What do I need to know? Am I able to just pull the gearbox back and slip it down the drivetrain?
Do I need to take the Driveshafts out of the bellhousing area?
Can I get away with not having to bleed the clutch?
Do I need to drain the oil from my gearbox?
Is there extra things to do with the dual Range that I need to know?
All i am doing is replacing Clutch, PP and Throwout bearing. and Spigot bearing.
Cheers
replacing Clutch for First time
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AlpineRaven
- Senior Member
- Posts: 3682
- Joined: Wed Oct 19, 2005 10:00 am
- Location: Melbourne, Victoria, Australia.
With Dual Range boxes is more work than FWD Subarus.
You will need to remove the tail shaft, mark it so that you can line them up again to keep the balance, front drive shafts has to be removed too, exhaust pipe (from engine manifold to 3/4 way) also has to be removed as well as it'll be in the way.
You will need to drain the gearbox out otherwise you'll have oil everywhere.
with Dual Range, you will need to disconnect the cable - best easy option is to undo the bolts/bracket on the gearbox that is holding the dual range section..
Clutch - just un-mount it - i dont think you need to bleed it.
Starter Motor has to be removed - disconnect the battery before you start.
You should replace the pinot bearing on the flywheel, bearing nbr is 6201.
Its recommended if you could align up the new clutch best as possible, i have an old input shaft from an subaru gearbox as clutch alignment tool.
Cheers and good luck!
AP
You will need to remove the tail shaft, mark it so that you can line them up again to keep the balance, front drive shafts has to be removed too, exhaust pipe (from engine manifold to 3/4 way) also has to be removed as well as it'll be in the way.
You will need to drain the gearbox out otherwise you'll have oil everywhere.
with Dual Range, you will need to disconnect the cable - best easy option is to undo the bolts/bracket on the gearbox that is holding the dual range section..
Clutch - just un-mount it - i dont think you need to bleed it.
Starter Motor has to be removed - disconnect the battery before you start.
You should replace the pinot bearing on the flywheel, bearing nbr is 6201.
Its recommended if you could align up the new clutch best as possible, i have an old input shaft from an subaru gearbox as clutch alignment tool.
Cheers and good luck!
AP
Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
in my forester i removed the tail shaft but didnt need to remove the drive shafts.
mark and remove tail shaft.
remove exhaust headers.
clutch can be unbolted from top of gearbox and moved out of the way.
hi-lo cable needs to be disconected, i did this in the cabin.
big trolly jack under gearbox, undo all bolts to engine and mounts to body... remember there is wiring that will need undo'ing.
slide it back and down a bit.
remove and replace parts.
put it back the same way it came apart.
i cant remember if i removed my shifter linkages and if removing flywheel you'll need lock the flywheel with either a socket on the crank or a plate with two holes. bolted from flywheel to engine block.
i did mine on while the car was up on ramps at the front and some stands at the rear.
mark and remove tail shaft.
remove exhaust headers.
clutch can be unbolted from top of gearbox and moved out of the way.
hi-lo cable needs to be disconected, i did this in the cabin.
big trolly jack under gearbox, undo all bolts to engine and mounts to body... remember there is wiring that will need undo'ing.
slide it back and down a bit.
remove and replace parts.
put it back the same way it came apart.
i cant remember if i removed my shifter linkages and if removing flywheel you'll need lock the flywheel with either a socket on the crank or a plate with two holes. bolted from flywheel to engine block.
i did mine on while the car was up on ramps at the front and some stands at the rear.
sorry to anwser your questions,
1. i didnt need to, but i can see how it would make the gearbox easier to move.
2. the clutch slave cyclinder on the gear box can be undone and moved out of the way. no need to bleed as its not being opened
3. i didnt drop much oil, so i just topped it up a little.
4. other than a extra cable running to a selector (for hi/lo) there is nothing extra. unless your use to rwd boxes, then theres the two drive shafts up front...
1. i didnt need to, but i can see how it would make the gearbox easier to move.
2. the clutch slave cyclinder on the gear box can be undone and moved out of the way. no need to bleed as its not being opened
3. i didnt drop much oil, so i just topped it up a little.
4. other than a extra cable running to a selector (for hi/lo) there is nothing extra. unless your use to rwd boxes, then theres the two drive shafts up front...
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AlpineRaven
- Senior Member
- Posts: 3682
- Joined: Wed Oct 19, 2005 10:00 am
- Location: Melbourne, Victoria, Australia.
Oh yeah I forgot to add, you will need to disconnect the shifter on the gearbox. 6mm split pin is there
Cheers
AP
Cheers
AP
Subarus that I have/had:
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
1995 Liberty "Rallye" - 5MT AWD, LSD - *written off 25/8/06 in towing accident.
1996 Liberty Wagon - SkiFX AWD 5MT D/R, Lifted.. Outback Sway Bar, 1.59:1 Low Gearing see thread: 1.59:1 in EJ Box Page
Sold at 385,000kms in July 2011.
2007 Liberty BP Wagon, 2.5i automatic
Cheers guys.
I ended up not getting enough time to complete the job so I got it down to my local Workshop. (first time there, great bunch of guys who rang around other places to see who could fit me in for the day, and they Towed it for free both ways)
however, I got it back and now 3rd and 5 both seem to be to the left a bit, you can go straight up from second and then going into fourth from 3rd is like going from first to fourth. and then straight up into 5th, Seems a bit odd. Any Ideas?
I ended up not getting enough time to complete the job so I got it down to my local Workshop. (first time there, great bunch of guys who rang around other places to see who could fit me in for the day, and they Towed it for free both ways)
however, I got it back and now 3rd and 5 both seem to be to the left a bit, you can go straight up from second and then going into fourth from 3rd is like going from first to fourth. and then straight up into 5th, Seems a bit odd. Any Ideas?