Tools and Materials Needed:
- Various wrenches
- Socket set
- Screwdrivers
- Pry bar
- Transmission jack (recommended)
- Clutch alignment tool
- New clutch kit (includes clutch disc, pressure plate, and throwout bearing)
- Flywheel resurfacing service or a new flywheel
- Transmission fluid
- Brake fluid
Step-1: Prepare the Car
- Park your car on a level surface.
- Engage the parking brake and chock the wheels.
- Disconnect the negative terminal of the battery.
- Remove the transmission access cover if there's one.
- Drain the transmission fluid from the drain plug.
Step-2: Remove the Transmission
1. Unbolt the transmission mounts.
2. Disconnect the shifter linkages and electrical connectors from the transmission.
3. Remove the driveshafts.
4. Support the transmission with a transmission jack.
5. Remove the bolts holding the transmission to the engine.
6. Carefully separate the transmission from the engine.
Step-3: Replace the Clutch
1. Inspect the flywheel for wear and scoring. If necessary, resurface the flywheel or install a new one.
2. Remove the old clutch disc and pressure plate.
3. Install the new clutch disc, ensuring proper alignment.
4. Install the new pressure plate and tighten the bolts in the specified sequence and torque.
5. Install the new throwout bearing.
6. Reattach the transmission to the engine.
Step-4: Reinstall the Transmission
1. Reinstall the driveshafts.
2. Reconnect the shifter linkages and electrical connectors.
3. Install the transmission mounts.
4. Refill the transmission fluid through the fill plug.
5. Bleed the clutch hydraulic system (if necessary).
6. Reconnect the battery.
Step-5: Test-Drive and Inspect
1. Test-drive the vehicle to ensure proper clutch operation.
2. Inspect for leaks and proper functionality.
Note:
- Clutch replacement is a complex task and requires precision. If you're a DIY enthusiast, ensure you have the necessary skills and tools to perform the job correctly.
- It's highly recommended to refer to the specific service manual for your vehicle's year, make, and model to obtain accurate and detailed instructions for your particular Subaru Outback.
