Clutch Change

Has anyone swapped out a clutch? I've heard of two methods, one removing the tranny, and the other removing the radiator so the engine can be shifted forward. Which is easier? Also, I found a tutorial on scoobymods, but it wasn't that great. Anyone know of some others? Is there a Chilton, or Haynes manual for our car somewhere? I've seen the 8 book collection for 400, but I wanted to avoid getting that huge collection. Thanks for the help in advance. It seems Rally Cheraw ate up my clutch pretty bad. Although it was close to the time to swap anyways.

 

Does Sakari have a warehouse where they would have clutches on site to pick up, or do they ship from somewhere else? I haven't been able to find a contact number for Sakari, and I don't want to wait for a response from an email, since this clutch needs to be shipped out today because there is a race this weekend.

 

i believe sakari's warehouse is in miami

 

Here is what we did for our sti:

Removal:
-remove IC
-remove engine pitch mount
-remove starter
-remove clutch slave
-remove clutch release pin, lifting fork out of release bearing
-disconnect wiring harness connectors near pitch mount for diff (3 connectors)
-lift car up off ground and put on stands
-remove bottom part of steering joint and lift allow room to store the starter to sit while dropping tranny
-remove full TBE
-drain tranny
-remove diff protector plate (6 bolts)
-remove propeller shaft (4 bolts + 2 for mount)
-cover propeller shaft point on tranny
-remove front wheels
-disconnect swaybar endlinks from control arms
-remove bolts holding abs cables and brake lines to struts (4 bolts)
-undo front strut attachments from hubs
-disconnect lower ball bolts, lift hubs from ball joint, pull axle splines from transmission, push axles aside, and put hubs back on ball joints (need help for this step)
-put jack under transmission, and remove 6 - bolts holding the mount to the chassis
-remove bolts connecting tranny to engine
-push tranny counterclockwise to give room to remove shift linkage and reverse cable
-lower transmission from car
-swap flywheel, clutch, pressure plate

.. then reverse process

--
Brian

 

Thanks for the help Brian. About how long did it take you? And does the car need to be up really high to drop the tranny? Whats the torque spec on flywheel nut and clutch bolts?

 

mmhmmm.... burned that clutch up getting outta the ruts huh??

 

Yeah, I had a little too much fun with the extra power. I didn't feel it slipping in the sand, but I definitely smelled when I stopped to help get out of that sandtrap.

 

It took us way too long, as I put the clutch disk in backwards the first time... put the car all the way back together, and had to drop the whole thing again.

I bet I could drop the tranny down in around 2 hours now. The hard part is lifting the heavy transmission up, which works best with 3 people. It should be easier with 3 people. If it is your first time, I would guess 3 hours dropping the tranny, and 3 hours to put it back together.

For the height, I just had it as high as the jack would let me put it on the jackstands, probably 2' - 2.5' off the ground.

As for the torque spec, check the service manual, as I forget the numbers.

--
Brian

 

No service manual. I was wondering where to pick one up. The only one that I saw was the 8 volume set, but not sold individually, http://www.fastwrx.com/subimsermans.html.

 

I just changed my clutch in my 4x4 Tacoma and that was a pain in the ass.

1. Have another car handy if you need to get parts or tools. You will.
2. Get or borrow a scissor transmission jack.
3. Use an impact wrench to break all bolts lose. I did the first half by hand about killed myself straining with a socket wrench and pipe for leverage.
4. Rent a pilot bearing puller from a store. When you want to put the new one in, put it in a zip lock in the freezer for a couple hours to shrink it and make it easier to hammer in with scrap wood or appropriate sized socket.

It will probably be easier on the Subaru except for removing the front drive shafts. A crawler will come in very handy. If you are doing yourself be prepared for the whole weekend if not longer. Have a spare car ready to get to work on Monday, but be satisified in saving all the labor some shop would charge and that you did it yourself.

 

Just changed the clutch in the STi 2 weeks ago. 3-5 hr job depending on your work area. I had a lift and all the proper jacks. Much easier than doing the job on your back.

I had the "CLUTCH MAN" come and cut my flywheel for $45.

Pretty sure the it was 50 ft/lbs on the flywheel and 30 on the clutch bolts.

 

I picked a service manual off of the web somewhere. I have a 2002. I wouldn't be surprised if it gave good enough guidance for a 2003. I'll try to remember where I found it. At any rate, PM me if you want what I have.

Dean

 

Yeah, I found the service manuals in pdf format that you can download for 72 hours for $35. So far I have a few of the service manuals, but mainly the entire transmission manual. This was a great website for anyone that wants to DIY. http://techinfo.subaru.com/html/index.jsp. Just type in the model year and it gives you all of the information you could possibly need.

 

Well I downloaded the manuals already, but thanks for the help. I have been spending the last couple of days downloading as much as possible, since they only let you have 50 downloads per hour.