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Old 01-11-2012, 02:16 PM   #1
designer
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Default Source for a clutch assembly? clutch is going on my 2002 impreza 2.5 TS

My clutch is starting to go... If i am not careful there is a grinding noise when going into fourth, and it is getting harder and harder to engage into first... I was told it may be the throw bearing or a synchro...

Any thoughts?

My question then is... Do I replace the whole assembly or try to repair the single parts... My gut tells me I should replace the whole assembly, but I am no expert so please help me out guys/gals...

Also, where is a good source for the clutch? I have looked on Ebay but it is unclear whether or not the parts are specific to my vehicle.
A friend suggested Rock Auto as well. Also willing to consider aftermarket if anybody has any suggestions.
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Old 01-16-2013, 09:31 AM   #2
designer
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Default Clutch gone?

On my way to work today, the clutch pedal suddenly sunk and remained depressed... I managed to get to work but it was dangerous and probably not very good for the car. The car was making a loud humming noise as well, can anyone help me figure out what's going on???

My friend suggested hydraulic fluid but i've been having problems with this clutch for a while ( I know, I should have fixed it ) so I'm not sure what to do at this point... I've read on the forum it may be the clutch slave, possibly leaking, malfunctioning, or dirty fluid. Could this be as a result of a bad clutch? Its at a Midas next to my work at the moment getting the old "Midas touch", I asked them to diagnose it for me.

We'll see what they say.

Thanks guys...

Last edited by designer; 01-16-2013 at 12:00 PM.
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Old 01-16-2013, 11:56 AM   #3
rick-l
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Sounds like you sucked in some air in your clutch hydraulics. Fluid level probably got low through a leak. It uses brake fluid.
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Old 01-16-2013, 12:06 PM   #4
designer
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Default Slave

Yes I think you are right. I guess I will need to determine where the leak is coming from. Any guess?

I figure eventually I will need a new slave, master, and hoses... I'm planning on doing a full overhaul on this vehicle come springtime.
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Old 01-16-2013, 12:14 PM   #5
rick-l
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Quote:
Originally Posted by designer View Post
a new slave, master, and hose
That is all there is. I think all those are visible with the hood open.
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Old 01-16-2013, 01:30 PM   #6
Aaron'z 2.5RS
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start with the easy/cheap stuff, work toward the more expensive/harder...

Fluid first...
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Old 01-17-2013, 12:54 PM   #7
designer
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Ok well further inspection yields a failed slave cylinder, bent clutch fork, clutch is toast and flywheel may need resurfacing...

Proceeded to order a clutch kit ( disk, pressure plate, flywheel, and hardware) a new throw out bearing, clutch fork, and slave cylinder... All OEM components from eBay Subaru dealer...

Under 500 shipped not bad.

Next weekend I will be doing the work with a buddy of mine at his shop.

Can anyone provide tips for installation? Perhaps there is a thread with a step by step? I really want to take as much guesswork out of this as possible. Thanks everyone.
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Old 01-17-2013, 02:17 PM   #8
designer
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It's begun.. I guess I'm going to do the HGs and other recommended service... Including the Timing belt kit.

Anybody have any advice as to what kit to use? Money is tight right now...
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Old 01-23-2013, 09:30 AM   #9
designer
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Motor is out. Parts on the way including:

OEM Clutch w flywheel and throwout bearing

Timing kit including belt, water pump, pullies, and tensioner, also includes seals

Head gasket kit with assorted gaskets including exhaust gaskets

New spark plugs

So... Am I missing anything? Any tips for installing any of the above? Dos and donts? I've been looking at threads but not for this specific engine, I figure there is a general pattern in terms of assembly... Any advice is welcome.
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Old 01-28-2013, 04:32 PM   #10
designer
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Arghhhhh... So I did miss something. If some of you "experts" could have spared a moment of your time I may be driving my car by now...

There is a clip that attaches to the clutch fork / throwout bearing- when we disassembled the clutch there was no trace of this clip, both the fork and the throwout bearing were pretty beat up.

I got the head gaskets done, water pump and timing belt with tensioner and pulleys too. Finally it was time for the clutch- and that's when the panic started setting in (Sunday night, no way to get any parts)... No clip was included with the throwout bearing... Or a clutch alignment tool with the clutch "kit". Now I'm stuck without a car for another week (I can only get into the shop on weekends) - I guess I should have known better?

Well lesson learned, look at a parts diagram before trusting a "Subaru parts specialist" who says that will be all the parts needed... Damn it.
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Old 02-03-2013, 12:20 PM   #11
designer
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OK. Thanks for your time, I've been searching the forums with no luck thus far.

2002 Impreza 2.5 TS SOHC - MT - 170 k - All stock.

JUST REPLACED: Clutch (disc, flywheel, pressure plate, throwout bearing, fork arm) Head gaskets, timing belt, water pump, tensioner and pulleys and spark plugs, New starter and battery, new fluids all around

NOTES:

1. When I try to start the car, the starter clicks once but doesn't turn over.
2. Tested the starter out of the car, starter is functioning fine
3. Tried push starting the car, tried jumping the car - no result
4. Replaced battery and reseated connectors, checked fuses - all good
5. Checked the neutral safety switch- operating properly
6. No binding whatsoever when manually turning the engine over

WE ARE STUMPED. What am I missing??? Security system? Starter relay? ECU Problem? Please help!!!! I need my car - I can't afford another week without a car. Thank you.
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Old 02-03-2013, 05:03 PM   #12
yarrgh
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Did you end up installing that missing clip? You need it.

This is my first time seeing this thread. My first thought is: why did you disconnect the AC and PS? those systems are designed to be unbolted from the engine and laid aside so you don't have to mess with them.

Anyway, you say that you're able to rotate the engine manually, which is good. What I don't get is that even push starting won't work. When you use the starter, does it even try to rotate the engine? or just click with no effort behind it?

Did you remember to attach that 3rd wire to the starter? Are your cam/crank sensors plugged in? Are they plugged in correctly? I bent a pin on the crank sensor once and it would only start intermittently (although the starter would still spin the engine). Look at your owners manual for security issues, sometimes you have to deal with the black push-button under the steering wheel before anything will work.
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Old 02-03-2013, 10:00 PM   #13
designer
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Ok. Got it figured out. One of the wires connecting to the starter was hacked up pretty bad, it wasn't visible at first and we ended up splicing a new wire in.

As for the disassembly of the AC and PS, it's my first run at this so I wasn't sure what all we had to do... No real advice from the forum after I requested either. Fortunately we got it all back in place and now the car is running good. As for the AC, it wasn't very strong last summer so I figured since I'm going to get it charged up again this spring it wouldn't really matter if we removed it or not.

Anyway this whole process has been a great learning process. Thanks to all the forum members who contributed and look forward to being active in the future.
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Old 02-03-2013, 10:01 PM   #14
designer
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And yes I got the missing clips ( two to be exact)
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Old 02-04-2013, 10:06 PM   #15
subi400
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I went to replace and reseal the oil separator plate on the back of the engine and one of the clips for the throwout bearing was gone... Had to wait like a couple of days before I could get one....

Ting little....

But, glad to hear that you got everything back together. Make sure to lube the tranny snout where the throwout bearing glides on with some good grease, not too much but enough. Don't get any on the clutch disk though and lube the ball that the clutch fork pivots on as well.
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Old 02-05-2013, 08:00 AM   #16
Aaron'z 2.5RS
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You didn't read anything did you.... considering he's got the car running now...
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