Hi, All -

 

The original clutch in my 1996 Outback 2.2 has finally started to slip. This car has been in our family since new, so we know its history.

 

Just wondering what parts should be replaced while the transmission is out, what brand of replacement parts to use, and if there  are any tricks with the 'hill holder' clutch. Here's what I've come up with so far:

 

replace clutch disc (any preferred brands?)

replace throwout bearing (+ 2 clips?)

replace pilot bearing

replace pressure plate

machine or replace flywheel

replace oil separator and screws (seal with permatex)

replace rear main seal

 

Any tricks with the 'hill holder' clutch? Do I also have to replace transmission fluid? Would you use Redline 75w90NS? Anything I'm missing?

 

Any information or confirmation that this is the right approach would be helpful. Looking forward to the next 200k miles.

 

Thanks!

 

Aaron

Exedy is the preferred brand for subaru. Kits are best priced on ebay and amazon.

 

Scratch the rear main seal off the list unless it is leaking (Weeping is ok) there is higher likelihood of it leaking after replacement than if it's left alone. 

 

Inspect the clutch fork for cracks etc. re-grease the ball on the clutch fork and the shaft/throwout bearing. There's a good writeup on the whole clutch job if you need it, I can post a link. Gives good photos etc. on the whole process.

Well to start , pulling the motor is easier than pulling the tranny. Leave the rear main alone unless it's leaking.  reseal the oil separator & change out the o ring   behind the diamond shaped plate on the other side of the crankshaft. Be sure to use an impact screwdriver to loosen the screws or they will strip . Nothing to the hill holder system  loosen it up while you adjust your clutch then screw it back down till it just starts to move. Exedy is the prefered clutch and will come in a kit with all the other pieces you mentioned including an alignment tool . It will not come with the t.b. clips but i've always just reused them. Have them just clean up the flywheel don't let them take off much. 

Id recommend replacing the clutch fork while you have it apart. They are known for wearing at the pivot and breaking.

Replace the clips on the release bearing as well. They're only a few $ and will cause major problems later if they break.

Check the quill on the transmission for wear. The aluminum gets work and causes the release bearing to engage the pressure plate unevenly, this causes only partial engagement of the clutch and shuddering. If the quill is worn get a repair sleeve kit. Some new clutch kits come with the sleeve and matching TOB.

I've used the Grip Force Kits off of Ebay and have been happy.  

Other important things have been covered.

Larry