Bought another Subaru Outback, weird clutch prob, please help me diagnose

[RANDY P]

Originally Posted by pen15

If you have to do the job on jack stands and have lots of time it is less time on the creeper to just pull the engine. All that needs done underneath is a few bell housing bolts, two nuts for motor mounts and six bolts for exhaust. Takes a few hours longer but much easier handling an engine with a cherry picker than wrestling a trans on a floor jack.

Great time to clean the engine bay and reseal the engine too. Would make it a worthwhile hassle.

rjp

[RANDY P]

One last thing: Anyone have a good reliable source for rebuilt long block for a non-turbo car? I can't seem to find a new OE longblock for a 4 cyl forester non-turbo, 2002. Trying to make this a one day operation, remove, reinstall a new engine.

Anyone done biz with a rebuilder that ships?

rjp

[DonDavis]

Ok, we pulled the engine yesterday.

Wow, the clutch was roasted. What really surprised me is I couldn't smell any odor at all when we first saw the car. And I've never dealt with a clutch this trashed.
The flywheel was toast as well. Covered in heat/stress cracks. Replacing that, too.

The valve covers are dry, zero leaks. We have new ones on hand, but I'm thinking leave them alone. Let sleeping dogs lie, right?

Manual calls for NGK BKR5E-11, but the car has NGK PFR5B-11 ( Platinum ). Saw some online comments about not using platinum. Think we'll stick with what the manual calls for.

Looks like the oil pan gasket is the only leak. We'll replace that.
If things go well today, we could have it back in tonight.

[eddie914]

"Clutch disc worn out ... Completely?!?!"

[john70t]

Still plenty of metal there.
Just rough up the surface with a scotchbrite.

[fastfredracing]

That looks exactly like the last one I did. It is not often I get to see one so worn out that it will not even attempt to move the car.

[DonDavis]

Originally Posted by eddie914

"Clutch disc worn out ... Completely?!?!"

First reply nailed it.