EJ25 Outback Clutch Replacement Issues

Dave00 · Post by **Dave00** » Sun Mar 17, 2013 7:23 pm

Hi there,

I recently bought a 2001 Subaru Outback and I'm pretty happy with it. However, I bought it knowing the clutch would need to be replaced: it was beginning to slip and had a cold clutch shudder.

I was told (twice) by my local Subaru dealer (who had past history on it) that this particular model had a dual mass flywheel fitted and they quoted me about $1800 to do a conversion to single mass flywheel and clutch replacement.

I did some research and decided that I'd prefer to use an Exedy single mass conversion kit since the quality was good but it was a bit cheaper (I know, but I'm a student). So I ordered a FJK-7374SMF kit from an Exedy distributor and gave the kit and car to my mechanic on Friday to have the clutch replaced.

It didn't go so well. I got a call from the mechanic not long after to say that they had pulled out a single mass flywheel and the replacement from the kit did not look as if it would fit. I'm glad he didn't just shove it in there. I should also say that the mechanic called a different Subaru parts dealer and they identified the car as being fitted with a single mass flywheel. Interesting...

I called Exedy direct and spoke to a helpful fella there that made it sound as if this happened a lot. He actually said sometimes it seemed Subaru had fitted whatever type of clutch was immediately to hand on the production line and hadn't been particularly careful about recording which car had got which clutch set-up. He said if it wasn't dual mass it was either solid OEM or a flex flywheel (identifiable by a steel plate bolted to the back with a ring of bolts). He also said that if it was solid OEM, then I could use a FJK-7115 Exedy kit, but if it was flex then I'd need an FJK-7626SMF kit which contains a new flywheel as well as some more stuff like a throwout fork and things to make sure everything fits with the appropriate tolerances. He said it isn't a good idea to machine a flex flywheel. I think he also said the FJK-7626SMF kit could be used whichever the old type was because everything was replaced and so would work together. The mechanic said the steel plate and ring of bolts is on the back, so I've ordered that kit even though it's more expensive, in the hope that I'll pay a little more but it's guaranteed to actually work! It's coming from interstate and the distributor is happy to swap it with the wrong kit (as long as it's in reasonable condition) and I'll pay the difference.

I read an old thread about a similar thing on an Impreza, but thought I'd start a new thread since that one was so old.

I'm really just hoping that the new kit I've ordered will work and that I won't waste anymore time or money! I was thinking though, maybe the cold clutch shudder and heavy clutch that it had when I bought it is a symptom of the clutch it had when I bought it being incorrect.

Any thoughts?? It's hard to know what's going on when Subaru dealers are saying different things... I'll probably call Exedy again tomorrow to make sure this kit will work and also call the Subaru dealer to see if they have a record of the clutch being replaced before. Any input from someone who knows more about this stuff would be appreciated. At the moment I'm going with "if we replace as much as possible in the clutch assembly then it's bound to work". I should get the new kit tomorrow and give it to the mechanic so if you know something don't delay in replying! I'll post to let you know what happens too.

taza · Post by **taza** » Sun Mar 17, 2013 8:45 pm

Very interesting about what the guy from Exedy said...

I have a single mass in my 2001 Forester, I'm on the 2nd clutch and the original was single mass also. I found that both clutches have a shudder when cold. I know a dual mass setup is designed to allow smoother gear changes for a better ride.

I also know that my mates 2003 Outback (Gen3, same as yours) has a dual mass flywheel. It had star pattern bolts, 4 of which rounded and were a FPITA to get out.
If this is definitely the right kit, atleast it's mentioned on here for future reference

RSR 555 · Post by **RSR 555** » Mon Mar 18, 2013 11:44 am

The 1999 Outback (EJ25 SOHC) onwards all used the Dual Mass Flywheel, so yours may have been replaced with an aftermarket kit already in it's life. If this is the case, this could be the reason why the new kit looks different.

Is there any manifactures name on the pressure plate?

Dave00 · Post by **Dave00** » Mon Mar 18, 2013 1:38 pm

I was thinking that perhaps the clutch had been replaced before and converted to single mass when it was. I called the dealer who has the history for the car this morning and they don't have any history of a clutch replacement. They also said that their system allows either a single mass kit or a dual mass kit to be selected for my car, so it could be either. That is something they perhaps could've said earlier.

I took the new Exedy kit to the mechanic earlier today. The old parts (cover, flywheel, clutch plate etc) are Subaru genuine. We compared the old parts and those in this new Exedy kit and we had a few nervous moments when we thought the new stuff wouldn't fit again. After another call to Exedy and assembling the kit parts together on the bench, the general consensus is that it will work provided all the parts in the kit replace their older counterparts from the original assembly, including the clutch fork and bearing.

So, it'll be fitted sometime in the next few days. I'll let you know how it drives after that. Keep your fingers crossed for me...

NachaLuva · Post by **NachaLuva** » Mon Mar 18, 2013 5:43 pm

Its not very good you cant be given the right info from the dealers, or from the mechanic. I'd be hoping he could tell simply from looking at it exactly what sort of clutch setup you have. Is he a Subaru specialist?

Good luck, I hope you get it sorted soon

FROG · Post by **FROG** » Mon Mar 18, 2013 6:22 pm

Can you pm me your full vin number please Dave - Im a little interested in this
regards Andy

RSR 555 · Post by **RSR 555** » Tue Mar 19, 2013 2:45 pm

FROG wrote:Can you pm me your full vin number please Dave - Im a little interested in this
regards Andy

Me too Andy, because from my understanding, the solid mass flywheel conversion wasn't offered by Subaru until later??

Dave00, Subaru would not have the records if it was done by someone outside of Subaru, say like Automasters or similar. The original pressure plate would have been a Daikin Clutch (now know as Exedy) and the symbol on the original will look like this...

YouTube · Post by **El_Freddo** » Tue Mar 19, 2013 6:23 pm

I think this happened to Phizinza too - his "original" flywheel came out as a three piece

Cheers

Bennie

RX Coupe · Post by **RX Coupe** » Tue Mar 19, 2013 8:43 pm

I had Rising Sun convert my dual mass flywheel to solid flywheel when I needed my clutch replaced in my 02 Outback. It cost about $1000.

NachaLuva · Post by **NachaLuva** » Tue Mar 19, 2013 10:12 pm

RX Coupe wrote:I had Rising Sun convert my dual mass flywheel to solid flywheel when I needed my clutch replaced in my 02 Outback. It cost about $1000.

Thats what my sister has been quoted for her '06 Outback

Dave00 · Post by **Dave00** » Sat Mar 23, 2013 2:39 pm

I collected the car yesterday. I managed to get a refund for the incorrect clutch kit and paid $1100 for the FJK-7626SMF clutch kit from the distributor back on Monday.

The car drives nicely now and the new clutch operates much better; it's not as heavy and engages nicely. My only complaint is a little vibration if I load it up - say if I try to accelerate hard from under 2000rpm in second gear. I generally don't (and shouldn't) do that anyway though, so mostly I'm happy with it.

Remember the mechanic has been pretty good. He wanted to replace it with an OEM single mass flywheel kit and got information which turned out to be accurate off an alternative dealer. It was my fault for relying more on what the other dealer had told me - that is where the issues developed. If I had let him pull whatever was in there out and have a look and then order Subaru parts, it would've cost about $1300 all up. Instead I paid $1100 for the Exedy kit and the usual labour costs, plus for some reassembly and dismantling again when they had to get my car out of the way while we waited for parts and they found time in the timetable to do it again. So it ended up costing me around $1900 which hurts quite a bit. Mostly my fault though. Perhaps a lesson there. If I had let the dealer do it, they either would've charged me less than $1800 (if they realised their mistake when they took the old clutch out and then used different parts) or the $1800 originally quoted based on it begin fitted with the dual mass flywheel. If I had just handed it to the (non-dealer) mechanic and asked for Subaru parts it would've been $1300, but they would've machined the flex flywheel instead of replacing it.

The mechanic did quote me $1000 for the clutch change with different aftermarket parts. I wanted to use Exedy which was a bit more expensive if all had gone smoothly.

"Dave00, Subaru would not have the records if it was done by someone outside of Subaru, say like Automasters or similar. The original pressure plate would have been a Daikin Clutch (now know as Exedy) and the symbol on the original will look like this..."

Yeah, I realise that. It may have been done before. All I know is the dealer that has records on it doesn't have a record of the clutch being replaced and Subaru parts were in there. Whether it was the original clutch or a Subaru replacement that was done by another party I don't know. Remember one dealer did say the original clutch was single mass though. However, I was told by the dealer with its history that the single mass conversion has only been offered later also. So everyone just seems to say different things. Hence the confusion!

So I'm still generally unsure what went on and why everyone involved thought different things, but I can tell you that the FJK-7626SMF Exedy kit is a reasonable replacement in this particular case (single mass fitted whether original or not).

If anyone does find out anything interesting though, do let me know. Hopefully, if nothing else, someone may find my experience helpful.

taza · Post by **taza** » Tue Jan 07, 2014 8:11 pm

Thought id revive this thread...
On Saturday a few of us are doing the clutch on a SG(2004) non turbo EJ251 Forester.
I'm fairly sure they are Dual Mass Flywheel as standard. We are pulling the gearbox out and installing a SF gearbox(for the better gearing) and doing the clutch.
We want to change it to a Single Mass Flywheel.
I was looking at the Exedy JFK-7374SMFHD kit which is listed as the Single Mass Flywheel conversion kit which included a heavy duty clutch kit with spigot and thrust bearings for this particular Forester.

I just want to be sure I order the correct kit as we are ding the conversion on a weekend and it's planned to be done in a day

Can anyone point me in the right direction?
Also I tried sourcing this kit from Covs and Veales with no luck in Perth. Any recommendations?

-Taza

Post by **TOONGA** » Tue Jan 07, 2014 10:44 pm

Subaru ?

http://www.ebay.com.au/itm/GENUINE-Suba ... 1c38499649

Bunbury Subaru

TOONGA

taza · Post by **taza** » Wed Jan 08, 2014 8:53 am

Yes it's a Subaru forester.
Don't want a genuine kit due to cost and the clutch isn't heavy duty. .

Dave00 · Post by **Dave00** » Wed Jan 08, 2014 1:53 pm

The JFK-7374SMFHD kit should work provided the original is a DM flywheel. If it turns out not to be, you'll need a different kit. My troubles came about because I thought my outback had a DM flywheel, but it turned out it didn't when the old one was pulled out. A dealer might be able to tell you whether there's likely to be another possibility other than DM. It also depends whether it's already had a SM conversion done. I got my kit through ABS, but you can find other distributors using the Exedy Australia website. Hope this helps. I'd be interested to hear how the replacement work goes.

Post by **TOONGA** » Wed Jan 08, 2014 7:37 pm

taza wrote:Yes it's a Subaru forester.
Don't want a genuine kit due to cost and the clutch isn't heavy duty. .

I meant have you tried Subaru?

As for heavy duty clutches you will be hard pushed to get one to suit a dual mass conversion kit in WA, let alone the East Coast.

TOONGA

taza · Post by **taza** » Wed Jan 08, 2014 9:06 pm

Got a single mass conversion kit. Exedy kit for $680 In Perth.