The clutch went up in smoke!

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So driving home from the dog park this evening, I take off (gently) at a set of lights and notice a bit of a shudder and not a great deal of 'pedal' before it grabbed. Next few gear changes sees the pedal shrinking even further to the floor. Get to the next set of lights and have my foot to the floor... revs start dropping and the car starts edging forwards. Take the car out of gear... try to put it back... GRRRRRIIINNNNDDDD... Turn the car off, smell burning clutch smell, notice plumes of smoke pouring out from under the car. Right at a busy intersection too. A generous bystander helped me push it up a side street out of harms way and I waited for a tow.

I really hope I haven't fallen prey to the infamous dual flywheel dramas which Gen 3s are known for because it's going to stretch the budget enough even if it's just the clutch. It had always had a canary under the bonnet (except with clutch engaged) sound since I got it 35,000kms ago (now at 165,000)... In hindsight, maybe I should have shown more concern about this...

I'll keep you updated over the next week with the findings

Cardboard Tube Samurai
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Re: The clutch went up in smoke!

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If you have 165,000km on the factory clutch, your doing pretty well. The life on a factory clutch is about 100 to 150,000kms. I have heard that Subaru clutches usually wear out quite quickly.

My clutch squeaks and I find it troublesome on hill starts. Im not sure really what it is, and I have never had issues with previous car clutches but the one in my Legacy just doesnt handle high revving launches. I recently overloaded the clutch on a hillstart and left a heap of clutch smoke behind the car - very embarassing!

BigWillieStyles
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Re: The clutch went up in smoke!

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They don't love hard revving launches as I'm pretty sure Subaru designed them to be the weaker link in the drivetrain.
If you dump the clutch in a rwd or fwd you spin the wheels taking the load off the drivetrain. With our cars it's not that easy..somthings gotta give I guess. I got 150,000 outta my clutch ( longer than my headgaskets!)
Hope it's an easy fix for you!

got Nang?
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Re: The clutch went up in smoke!

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got Nang? wrote:

They don't love hard revving launches as I'm pretty sure Subaru designed them to be the weaker link in the drivetrain.
Yeah I have heard that before somewhere.

BigWillieStyles
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Turbosmart BOV :)

Re: The clutch went up in smoke!

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I got a call from the mechanic just before. It's nowhere near as catastrophic as expected. Apparently just a hose on the back of the gearbox or something (braided?). Only going to cost about $150. Looks like I dodged a bullet this time round

Cardboard Tube Samurai
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Re: The clutch went up in smoke!

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So I got a phonecall from the mechanic thismorning informing me that it wasn't just this hose. In fact the master cylinder is rooted too and it did take out the clutch. Funny that the master cylinder was dry because the reservoir was still full: must have had a blockage somewhere.

Cardboard Tube Samurai
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Re: The clutch went up in smoke!

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You might want to go and check out this rooted clutch for yourself. I don't really see how a failed master cylinder could cause your clutch to suddenly and catastrophically go up in smoke.
Also, you can run the reservoir completely dry and not kill the master cylinder, you just have no clutch pedal.
It is apparently very common for the flexible clutch hose (between the master and slave cylinders) to die on Subarus. I took mine in to a brake place and they instantly knew what it was off because they'd seen so many of them.

XoN
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Re: The clutch went up in smoke!

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I understand what you're saying but this guy is one of those incredibly rare mechanics who doesn't actually take you for a ride with these sorts of things. He has actually talked me out of getting work done in the past a couple of times because it was not needed. I've mentioned this in another thread "Clunking when turning" how he could have charged me a sh!tload of money to completely replace the CVs (and I would have believed it was required!) but instead just cleaned them up because they were mostly ok. If it is in fact the original clutch, I think 165,000 kms is a pretty good run. He's a bit pricey but it's worth it. The actual mechanic (as opposed to the business owner) is a former Subaru mechanic too apparently

Cardboard Tube Samurai
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Re: The clutch went up in smoke!

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I got the car back today... $1978.05 later!!! The throw-out bearing had seized and taken out the clutch and the clutch arm. Now sporting a solid mass flywheel setup which is quite different feeling to the dual mass setup. I think I like it though because it feels much more 'connected' to the engine revs. I didn't even have to ask for the solid setup and I'm guessing the former Subaru mechanic knew about it.

Oh and I also got proof of it all when he showed me the scraps of metal formerly known as bearing and clutch parts. I took pics which I might upload later if I can be arsed

Cardboard Tube Samurai
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Re: The clutch went up in smoke!

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Cardboard Tube Samurai wrote:

I got the car back today... $1978.05 later!!! The throw-out bearing had seized and taken out the clutch and the clutch arm. Now sporting a solid mass flywheel setup which is quite different feeling to the dual mass setup. I think I like it though because it feels much more 'connected' to the engine revs. I didn't even have to ask for the solid setup and I'm guessing the former Subaru mechanic knew about it.

Oh and I also got proof of it all when he showed me the scraps of metal formerly known as bearing and clutch parts. I took pics which I might upload later if I can be arsed
Damn, hope your happy with the end result.

I got into my car today after not driving it for a week or so and the clutch pedal was really stiff. Still changes gear fine. I think when I burnt the clutch I must have done some major damage. When the clutch is burnt, does the master/slave cylinder fluid burn off? Curious if it may be an easy fix. If its the clutch, I will be opting for one of the Exedy ones available.

BigWillieStyles
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Fujitsubo diff back
Zerosports metal intake elbow
Cusco front strut brace
Cusco front and rear swaybars
Apexi boost gauge
Turbosmart BOV :)

Re: The clutch went up in smoke!

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Cardboard Tube Samurai wrote:

I got the car back today... $1978.05 later!!! The throw-out bearing had seized and taken out the clutch and the clutch arm. Now sporting a solid mass flywheel setup which is quite different feeling to the dual mass setup. I think I like it though because it feels much more 'connected' to the engine revs. I didn't even have to ask for the solid setup and I'm guessing the former Subaru mechanic knew about it.

Oh and I also got proof of it all when he showed me the scraps of metal formerly known as bearing and clutch parts. I took pics which I might upload later if I can be arsed
I actually know another Liberty owner that happened to, but he knew his throwout bearing was rooted and chose to ignore it...
That price doesn't sound too far off, at least half of it would be labor costs for removing the gearbox, which is a massive pain in the ass!

XoN
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Re: The clutch went up in smoke!

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Cardboard Tube Samurai wrote:


That price doesn't sound too far off, at least half of it would be labor costs for removing the gearbox, which is a massive pain in the ass!
I reckon its prefectly inline with what dealerships charge, but a private mechanic would be cheaper.

I had my clutch on my old prelude cost me 700 all up including replacement clutch. Labour was about 300ish. Honda dealership wanted 3K to do the same job.

Its a days job, probably less for someone more experienced with Subaru's. Labour shouldnt be more than a days work.

BigWillieStyles
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Legacy GT-B
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High flow cat
Fujitsubo diff back
Zerosports metal intake elbow
Cusco front strut brace
Cusco front and rear swaybars
Apexi boost gauge
Turbosmart BOV :)

Re: The clutch went up in smoke!

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Will, Clutch Fluid shouldn't get hot from slipping the clutch, the master and slave cyl are not actually near the clutch as such.
it's not hard to drain the fluid anyway if you have a spare 15 mins. same deal as brake bleeding, tube onto the bleed nipple, pump clutch and hold, release nipple then just before loose all pressure close and then lift pedal up manually. repeat 10 times and keep topping up the reservoir.

cooked fluid would exhibit a soft pedal that would not dis-engage clutch correctly.
hard pedal could simply be the piston needing a bit of grease or.. the clutch pedal spring needing a bit of grease.

CodeBurn3r
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Re: The clutch went up in smoke!

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CodeBurn3r wrote:

Will, Clutch Fluid shouldn't get hot from slipping the clutch, the master and slave cyl are not actually near the clutch as such.
it's not hard to drain the fluid anyway if you have a spare 15 mins. same deal as brake bleeding, tube onto the bleed nipple, pump clutch and hold, release nipple then just before loose all pressure close and then lift pedal up manually. repeat 10 times and keep topping up the reservoir.

cooked fluid would exhibit a soft pedal that would not dis-engage clutch correctly.
hard pedal could simply be the piston needing a bit of grease or.. the clutch pedal spring needing a bit of grease.
thanks mate, will give it a go. I drove the car this afternoon, and wasnt really sure if I was imagining it. The clutch isnt slipping yet which is probably a good sign. But when I get a decent job, I will probably need to change the clutch.

BigWillieStyles
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Legacy GT-B
Custom 3inch catback
High flow cat
Fujitsubo diff back
Zerosports metal intake elbow
Cusco front strut brace
Cusco front and rear swaybars
Apexi boost gauge
Turbosmart BOV :)

Re: The clutch went up in smoke!

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Clutch can be changed at home if you pull the engine.. i think its easier pulling the engine if you are doing it at home..
unless you have access to a car hoist.. then you'd be stupid not to drop the box and do it that way tongue

CodeBurn3r
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Re: The clutch went up in smoke!

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Yeah I would not be in a hurry to drop the box on a driveway again. Even with 4 people it's a royal pain.

XoN
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Re: The clutch went up in smoke!

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I got the Excedy clutch kit put in. Feels great to drive now, highly recommended.

Breakdown on the bill was roughly:

$870 for clutch kit
$600-$700 for labour (bear in mind they did the master cylinder and replaced the hose too)

Cardboard Tube Samurai
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