97OutbackCA

Yup, I think we are going to be pulling the tranny and replacing the T/O and/or pilot bearing, and maybe the whole clutch set-up if it really is well worn. At this stage we might as well replace the master cylinder - as nipper said, they can leak internally and "hide" the fact that there is a problem. The final element will be to adjust the clutch pedal to factory specs. Thanks for all the help and ideas. Andy

I've had no leaks, no drop in the level of the master cylinder - the clutch was to the floor pretty much since we got the car - 115K miles. Nothing to suspect a bad MC. Brand of clutch - LUK, IIRC. Got new everything except flywheel - which was re-surfaced. Read a tech bulletin about a sticking slave cylinder which is what this did from time to time. Replaced it with genuine Suby parts per the tech bulletin. Never exprienced any clutch slip. I've had lots of vehicles with manual trannies - old stuff too - never experienced anything like this. Keep the ideas coming - this is getting interesting.

So what you are saying is that my clutch is worn out after just over 30K miles? Wow.

Somehow I doubt that the clutch is supposed to engage "right off the floor" meaning that the pedal had to be pushed into the carpet to disengage. This is what I had to do before I adjusted it. Now there is a bit of free-play when you press the pedal - ie nothing happens until the pedal is pushed in an inch or so. Thanks for your comments. As I said in my initial question - is it normal for the T/O bearing to ride on the clutch pressure plat and spin all the time? I doubt that. Therefore, how does one remedy this situation?

I think you may be right - we found there is a pedal adjustment under the dash at the firewall and adjusted that - the pedal had to be pushed to the floor before it would disengage the clutch - now there is a little bit of pedal play before the clutch disengages. I thing installing the new slave cyliner and flex line has helped also. But, sadly, you may be right about the T/O bearing - it sounds as though it is squealing most of the time. Andy

I searched the archives and can find no information as to adjusting a hydraulic clutch. One thread indicated that the newer hydraulic clutchs are not adjustable. When we replaced the head gaskets at 115K (pulled the engine) we also replaced the clutch and T/O bearing - my buddy is a tranny specialist and commented that the T/O bearing had been riding on the clutch. We have put about 30K on the car since that change. We have just replaced the clutch slave cylinder and the flex line and bled the system, but can now hear a "squeal" from the T/O bearing - when I jiggle the clutch fork I can feel it riding on the clutch - at least thats what it feels like. How can this be adjusted/remedied? Many thanks, Andy

plugs and wires replaced 30K miles ago when we replaced the head gaskets. Air filter was replaced a few thousand miles ago.

Our 97 Suby Outback Wagon (5spd) with 146K miles has an annoying "herky jerky" hesitation at low speeds in 1st and 2nd gear. It is a PITA in slow traffic - its as if there is a learner driver with clutch control issues Accelerating at higher speeds (45 to 50 MPH) I note that there is some minor jerkiness. Any ideas?? Many thanks, Andy

Hi: I just got my 97 Outback Wagaon a few months ago with 110K on the clock; everything works well. It has the noisy lifter issue at start-up - it goes away when the motor is warm. I am now getting the dreaded temp guage spikes every now and again - I am guessing this is an early sign of the head gasket going south. The previous owner told me that the HG had been changed at 70K. I am no stranger to shade tree mechanical work. I have the Haynes manual and have done quite a bit of serching on this most excellent site, and am aware of most of what is involved. My questions, though, are: 1) the job can be done without pulling the motor, however, is it one of those jobs where I might as well go the extra mile and pull the engine and make things easier? 2) what else should I be thinking of replacing while I am this deep into the motor? 3) This also speaks to the issue of pulling the engine, I guess, as I was wondering about clutch life expectancy, and related items. Thanks in advance, Andy in CA