WORKSHOP MANUAL

TBR SERIES

CLUTCH

SECTION 7C
 NOTICE

Before using this Workshop Manual to assist you in performing vehicle

service and maintenance operations, it is recommended that you
carefully read and thoroughly understand the information contained in
Section - 0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on the latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
 CLUTCH 7C-1

SECTION 7C
CLUTCH

TABLE OF CONTENTS

PAGE
Main Data and Specifications ......................................................................................... 7C- 2
General Description......................................................................................................... 7C- 3
Torque Specification ....................................................................................................... 7C- 7
Servicing........................................................................................................................... 7C- 9
Clutch................................................................................................................................ 7C- 11
Removal and Installation............................................................................................ 7C- 11
Inspection and Repair................................................................................................. 7C- 13
Clutch Control.................................................................................................................. 7C- 18
Removal and Installation............................................................................................ 7C- 18
Master Cylinder................................................................................................................ 7C- 19
Disassembly ................................................................................................................ 7C- 19
Reassembly ................................................................................................................. 7C- 20
Slave Cylinder .................................................................................................................. 7C- 21
Disassembly ................................................................................................................ 7C- 21
Inspection and Repair................................................................................................. 7C- 22
Reassembly ................................................................................................................. 7C- 23
Hydraulic Damper Cylinder............................................................................................. 7C- 24
Inspection and Repair................................................................................................. 7C- 24
Troubleshooting .............................................................................................................. 7C- 25
Special Service Tool........................................................................................................ 7C- 34
7C-2 CLUTCH

MAIN DATA AND SPECIFICATIONS

Clutch type Dry single plate with diaphragm
Size mm (in) 225 (8.858)
Clamping force kg(lb) 500 (1103)
(N) (4903)
Pressure plate
Outside diameter mm(in) 225 (8.858)
Inside diameter mm(in) 154 (6.063)
Driven plate
Thickness mm(in)
at free 8.2 (0.323)
at compressed 7.8 (0.307)
Clutch control type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Pedal height mm(in) 216-226 (8.50-8.90)
Master cylinder
Bore×Stroke mm(in) 15.87 × 35 (0.625 × 1.38)
Slave cylinder
Bore × Stroke mm(in) 20.64 × 16 (0.813 × 0.63)
 CLUTCH 7C-3

GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE

The clutch assembly consists of the pressure plate, the clutch cover, the diaphragm spring pivot pin and the driven
plate assembly.
The clutch pedal is connected to the shift block through the clutch shaft and the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
Diaphragm spring pressure holds the driven plate against flywheel and the pressure plate to provide the friction
necessary to engage the clutch.
Depressing the clutch pedal moves the shift fork against the shift block.
The shift block forces the release bearing against the diaphragm to overcome the force of the diaphragm spring and
separate the driven plate from the flywheel and pressure plate to disengage the clutch.
7C-4 CLUTCH

MASTER CYLINDER

The master cylinder converts mechanical energy into hydraulic energy.

Depressing the clutch pedal causes the push rod to move against the piston to close the return port.
Clutch fluid is forced out of the master cylinder.
Releasing the clutch pedal causes the return spring to force the piston back to its original position.
The return port is opened and the clutch fluid flows back into the fluid reservoir.
Quickly releasing the clutch pedal will cause the fluid pressure at the return spring side to be lower than the fluid
pressure at the push rod side.
This allows the fluid at the push rod side to quickly flow to the return spring side through a port in the piston head.
This equalizes the pressure at both sides of the piston.

SLAVE CYLINDER

The slave cylinder converts hydraulic energy into mechanical energy.

Hydraulic fluid supplied by the master cylinder moves the slave cylinder piston to actuate the shift fork.
The mechanical energy produced by the slave cylinder is directly proportional to the diameters of the master
cylinder and the slave cylinder.
A bleeder screw is provided to bleed the slave cylinder.
 CLUTCH 7C-5

HYDRAULIC DAMPER CYLINDER

The hydraulic damper cylinder is installed between the master cylinder and the slave cylinder to smooth out
variations in clutch pedal feel.
7C-6 CLUTCH

PRESSURE PLATE ASSEMBLY

The pressure plate assembly consists of the clutch cover, the pressure plate with diaphragm spring.
Operating the clutch pedal causes the pressure plate to move in an axial direction to engage and disengage the
clutch.

DRIVEN PLATE ASSEMBLY

The driven plate assembly consists of the plate and the facing.
The plate consists of the clutch center, the cushioning plate and the torsion springs.
The facing is riveted to both sides of the cushioning plate.
The cushioning plate provides a longer service life by minimizing wear and vibration at the clutch contact surfaces.
 CLUTCH 7C-7

TORQUE SPECIFICATION
STANDARD BOLTS

The torque values given in the following table should be applied where a particular torque is not specified.
N⋅m (kgf⋅m/lb⋅ft)
Strength 4.8/4T 7T 8.8 9.8/9T
Class Refined Non-Refined

Bolt Identifi-
cation

Bolt
Diameter× -
Pitch (mm)

Standard Hex. M6 × 1.0 6 (0.6 / 52 lb.in) 7 (0.7 / 61 lb.in) 8 (0.8 / 69 lb.in) -

M8 × 1.25 13 (1.3 / 113 lb.in) 17 (1.7 / 12) 20 (2.0 / 14) 24 (2.4 / 17)
Head Bolt
M10 × 1.25 27 (2.8 / 20) 37 (3.8 / 27) 42 (4.3 / 31) 50 (5.1 / 37)
M12 × 1.25 61 (6.3 / 45) 76 (7.8 / 56) 87 (8.9 / 64) 95 (9.7 / 70)
M14 ×1.5 96 (9.8 / 71) 116 (11.8 / 85) 133 (13.6 / 98) 142 (14.5 / 105)
M16 × 1.5 130 (13.3 / 96) 170 (17.3 / 125) 193 (19.7 / 143) 200 (20.4 / 148)
M18 × 1.5 188 (19.2 / 139) 244 (24.9 / 180) 278 (28.3 / 205) 287 (29.3 / 212)
M20 × 1.5 258 (26.3 / 190) 337 (34.4 / 249) 385 (39.3 / 284) 396 (40.4 / 292)
M22 × 1.5 332 (33.9 / 245) 453 (46.3 / 335) 517 (52.7 / 381) 530 (54.1 / 391)
M24 × 2.0 449 (45.8 / 331) 570 (58.2 / 421) 651 (66.3 / 480) 692 (70.6 / 511)
*M10 × 1.5 26 (2.7 / 20) 36 (3.7 / 27) 41 (4.2 / 30) 48 (4.9 / 35)
*M12 × 1.75 57 (5.8 / 42) 71 (7.2 / 52) 80 (8.2 / 59) 89 (9.1 / 66)
*M14 × 2.0 89 (9.1 / 66) 110 (11.2 / 81) 125 (12.7 / 92) 133 (13.6 / 98)
*M16 × 2.0 124 (12.7 / 92) 162 (16.5 / 119) 185 (18.9 / 137) 191 (19.5 / 141)
Flange Bolt M6 × 1.0 7 (0.7 / 61 lb.in) 8 (0.8 / 69 lb.in) 9 (0.9 / 78 lb.in) -
M8 × 1.25 15 (1.5 / 11) 19 (1.9 / 14) 22 (2.2 / 16) 26 (2.7 / 20)
M10 × 1.25 31 (3.2 / 23) 41 (4.2 / 30) 47 (4.8 / 35) 56 (5.7 / 41)
M12 × 1.25 69 (7.0 / 51) 85 (8.7 / 63) 97 (9.9 / 72) 106 (10.8 / 78)
M14 × 1.5 104 (10.6 / 77) 126 (12.8 / 93) 144 (14.6 / 106) 154 (15.7 / 114)
M16 × 1.5 145 (14.8 / 127) 188 (19.2 / 139) 214 (21.8 / 158) 221 (22.5 / 163)
M18 × 1.5 - - - -
M20 × 1.5 - - - -
M22 × 1.5 - - - -
M24 × 2.0 - - - -
*M10 × 1.5 30 (3.1 / 22) 40 (4.1 / 30) 46 (4.7 / 34) 54 (5.5 / 40)
*M12 × 1.75 64 (6.5 / 47) 78 (8.0 / 58) 89 (9.1 / 66) 99 (10.1 / 73)
*M14 × 2.0 97 (9.9 / 72) 119 (12.1 / 88) 135 (13.8 / 99.7) 144 (14.7 / 107)
*M16 × 2.0 137 (14.0 / 101) 178 (18.2 / 132) 203 (20.7 / 132) 210 (21.5 / 155)

The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as
casting, etc.

FLARE NUTS

Pipe diameter mm (in) Torque N⋅m (kgf⋅m / lb⋅ft) Pipe diameter mm (in) Torque N⋅m (kgf⋅m / lb⋅ft)
4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)
6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)
8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)
7C-8 CLUTCH

SPECIAL PARTS FIXING NUTS AND BOLTS

N⋅m (kgf⋅m/lb⋅ft)
 CLUTCH 7C-9

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.

CLUTCH PEDAL HEIGHT

Inspection
Measure to verify that the distance from the upper surface of
the pedal pad to the firewall is within the standard value.
Clutch Pedal Height to Panel (H) mm(in)
H 186.0 ± 5.0 (7.32 ± 0.20)

Adjustment
1. Loosen clutch master cylinder push rod lock nut 2 .
Turn push rod 1 by hand to set clutch pedal height (H) to
within specification.
2. After the adjustment, tighten lock nut 2 .
3. Turn the stopper bolt 3 until the stopper bolt 3 just touches
the clutch pedal arm.
Adjust stopper bolt 3 by backing it out half a turn, and
measure the clearance (L) between the clutch pedal arm
and the clutch stopper bolt 3 .
Lock the lock nut 4 .
Stopper bolt and clutch pedal
Clearance mm(in)
(L) 0.5-1.5 (0.020-0.059)

CLUTCH PEDAL PLAY

Inspection
Depress the clutch pedal lightly by hand, and measure to
determine if the free play is within the standard value.
Pedal Free Play mm(in)
H1 5.0-15.0 (0.2-0.6)
7C-10 CLUTCH

Bleeding Procedure
1. Bleed air from clutch operating cylinder according to the
following procedure.
Carefully monitor fluid level at master cylinder during
bleeding operation.

1. Set the paking brake.

2. Top up reservoir with recommended brake fluid.

3. Connect a transparent vinyl tube to air bleeder valve.

4. Fully depress clutch pedal several times.

5. With clutch pedal depressed, open bleeder valve to release

air.
6. Close bleeder valve.
7. Repeat steps 5 through 6 above until brake fluid flows from
air bleeder valve without air bubbles.
8. Bleed air from clutch damper according to the above
procedure.
9. Repeat the above bleeding procedure 1 and 2 several
times.
 CLUTCH 7C-11

CLUTCH
REMOVAL AND INSTALLATION

Removal Steps
1. Transmission assembly 6. Flywheel assembly and cran bearing
▲ 2. Pressure Plate assembly
▲ 3. Driven plate assembly Installation Steps
4. Release bearing To install, follow the removal steps in the
5. Shift fork reverse order.

Important Operations - Removal

1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of section 7B and 7B1
for “REMOVAL AND INSTALLATION” procedure.

2. Clutch Pressure Plate Assembly

3. Driven Plate Assembly
(1) Use the clutch pilot aligner 1 to prevent the driven plate
assembly 2 from falling free.
Clutch Pilot Aligner : 5-8840-2634-0
7C-12 CLUTCH

(2) Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3) Remove the pressure plate assembly 3 from the flywheel.
(4) Remove the driven plate from the flywheel.

Important Operations - Installation

Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.

3. Driven plate Assembly

2. Clutch Pressure Plate Assembly
(1) Clean the flywheel surface.
(2) Clean the facing surface.
(3) Use the clutch pilot aligner 1 to install the driven plate
assembly 2 to the flywheel 3 .
Clutch Pilot Aligner : 5-8525-3001 (J-24547)

(4) Clean the pressure plate surfaces.

(5) Align the pressure plate assembly 4 with the flywheel
knock pin 5 .
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the
numerical order shown in the illustration.
Clutch Cover Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
17.7 ± 2.9 (1.8 ± 0.3/13.1 ± 2.1)

(8) Remove the clutch pilot aligner.

Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.
 CLUTCH 7C-13

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

PRESSURE PLATE ASSEMBLY

Visually inspect the pressure plate friction surface for
excessive wear and heat cracks.
If excessive wear or deep heat cracks are present, the
pressure plate must be replaced.

Pressure Plate Warpage

Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the
pressure plate must be replaced.
Pressure Plate Warpage mm(in)
Limit
0.3 (0.012)

Clutch Cover
Visually inspect the entire clutch cover for excessive wear,
cracking , and other damage.
The clutch cover must be replaced if any of these conditions
are present.

1. Abrasion, scratches, cracks and deflection of friction face to

the disc, loose rivet and wear of ring.
• Grind small scratches, or replace the assembly if extreme
scratches are found.
7C-14 CLUTCH

Clutch Set Force

1. Position the pressure plate assembly 1 as shown in the
illustration.
2. Place the new driven plate 2 over the pressure plate
assembly.
Driven Plate Thickness (Reference) mm(in)
Standard
Free Compressed
8.2 (0.323) 7.8 (0.303)

3. Place a metal sheet 3 between the press and the driving

plate.
4. Compress the metal sheet and the driven plate until the
driven plate is flush with the drive plate assembly A .
5. Note the pressure gauge reading.
Driven Plate Slamping Force N (kg/Ib)
Standard
4.903 (500/1,103)
 CLUTCH 7C-15

Diaphragm Spring Finger Height

1. Place the appropriate spacer beneath the pressure plate.
Refer to the table below.
Spacer Thickness mm(in)
7.8 (0.307)

2. Fully compress the pressure plate and the diaphragm

spring.
There are two ways to do this.
1) Use a bench press to press down the assembly from the
top.
2) Tighten the fixing bolts.
3. Measure the spring finger height A from the base to the
spring tip.
Spring Finger Height mm(in)
30.5-32.5 (1.20-1.28)

Applying multi-purpose type grease (NLGI No.2 or No.3).

Shift Fork
1. Visually inspect the surfaces of the shift fork making contact
with the shift block for excessive wear and damage.
2. Remove any minor stepping or abrasion from the shift block
with an oil stone.
Replace any exhibiting excessive wear or damage.
3. Apply multi-purpose type grease (NLGI No.2 or No.3) to
area.

DRIVEN PLATE ASSEMBLY

1. Visually inspect the torsion spring 1 for looseness,
breakage, and weakening.
If any of these conditions are discovered, the driven plate
assembly must be replaced.
7C-16 CLUTCH

2. Visually inspect the facing surfaces 2 for cracking and

excessive scorching.
Visually inspect the facing surfaces for the presence of oil or
grease.
If any of these conditions are discovered, the facing must be
cleaned or replaced.

3. Check that the driven plate moves smoothly on the

transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed
with an oil stone.

Driven Plate Warpage

1. Insert the clutch pilot aligner into the driven plate splined
hub.
The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner : 5-8840-2634-0
2. Set a dial indicator to the driven plate outside
circumference.
3. Slowly turn the driven plate.
Read the dial indicator as you turn the driven plate.
If the measured value exceeds the specified limit, the driven
plate assembly and/or the facing must be replaced.
Driven Plate Warpage mm(in)
Standard Limit
0.7 (0.028) 1.0 (0.039)

Driven Plate Splined Hub Spline Wear

1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft
spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven
plate.
If the measured value exceeds the specified limit, the driven
plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear mm(in)
Standard Limit
0.5 (0.020) 1.0 (0.039)
 CLUTCH 7C-17

Rivet Head Depression

Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression 1 from the facing surface
2.
Be sure to measure the rivet head depression on both sides of
the driven plate.
If the measured value is less than the specified limit, the facing
must be replaced.
Rivet Head Depression mm(in)
Standard
Limit
Fly wheel side P/Plate side
1.35-1.95 1.65-2.25 0.2
(0.053-0.077) (0.065-0.089) (0.008)
7C-18 CLUTCH

CLUTCH CONTROL
REMOVAL AND INSTALLATION

Apply grease
(NLGI No.2 or No.3 grease)

Removal Steps Installation Steps

1. Pin 8. Damper cylinder assembly
2. Jaw joint pin 7. Slave cylinder assembly
3. Pedal assembly 6. Oil line
4. Oil line 5. Master cylinder assembly
5. Master cylinder assembly 4. Oil line
6. Oil line 3. Pedal assembly
7. Slave cylinder assembly 2. Jaw joint pin
8. Damper cylinder assembly 1. Pin
 CLUTCH 7C-19

MASTER CYLINDER
DISASSEMBLY

Disassembly Steps
1. Oil tank band 5. Packing
2. Oil tank assembly 6. Adapter
3. Yoke 7. Body sub assembly
4. Lock nut
7C-20 CLUTCH

REASSEMBLY

Reassembly Steps
1. Body sub assembly 5. Yoke
2. Adapter 6. Oil tank assembly
3. Packing 7. Oil tank band
4. Lock nut
 CLUTCH 7C-21

SLAVE CYLINDER
DISASSEMBLY

Disassembly Steps
▲ 1. Boot 4. Spring
2. Push rod 5. Cylinder body
3. Piston and piston cup 6. Solenoid switch

Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.
7C-22 CLUTCH

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it if
necessary.

Cylinder Bore and piston Clearance

1. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. Calculate the clearance between the cylinder bore and the
piston diameter.
If the clearance exceeds the limit, the entire slave cylinder
assembly must be replaced.
Cylinder Bore and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.006)

Piston and Piston Cup

Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts (Repair kit A) shown in
the illustration.
 CLUTCH 7C-23

REASSEMBLY

Apply grease
(Brake fluid)

Reassembly Steps
▲ 1. Cylinder body 4. Push rod
2. Spring 5. Boot
▲ 3. Piston and piston cup 6. Solenoid switch

Important Operations
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.

3. Piston and piston Cup

1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the
illustration.
3) Install the piston and piston cup to the cylinder body.
7C-24 CLUTCH

HYDRAULIC DAMPER CYLINDER

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

Visually check for oil leakage and other damage.

If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.
 CLUTCH 7C-25

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage
7C-26 CLUTCH

1. CLUTCH SLIPPAGE

Checkpoint Trouble Cause Countermeasure

NG No push rod play in the master

Clutch pedal free play Adjust the push rod play
cylinder

NG No push rod play in the slave

Adjust the push rod play
cylinder

OK

NG Insufficient grease on the front Clean and grease the shift

Shift block
cover contact surfaces block

NG Transmission front cover Repair or replace the

unevenly worn transmission front cover

OK

Grease or oil adhering to the NG Clean the related parts and/or

Too much grease
facing replace the facing

Clean the related parts and/or

NG Defective transmission front replace the facing
cover oil seal Replace the transmission front
cover oil seal

OK

Continued on the next page

 CLUTCH 7C-27

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK
Clean the related parts and/or
Grease or oil adhering to the NG Defective crankshaft rear oil replace the facing
facing seal Replace the crankshaft rear oil
seal

NG Release bearing broken Replace the release bearing

OK

NG Replace the driven plate

Facing Worn facing
assembly

OK

Clutch diaphragm spring NG Weak or broken clutch Replace the clutch pressure
diaphragm spring plate assembly
7C-28 CLUTCH

2. CLUTCH DOES NOT RELEASE PROPERLY

Checkpoint Trouble Cause Countermeasure

NG Too much push rod play in the

Clutch pedal free play Adjust the push rod play
master cylinder

NG Too much push rod play in the

Adjust the push rod play
slave cylinder
OK

NG
Hydraulic circuit Air in the hydraulic circuit Bleed the hydraulic circuit

OK

NG Driven plate warped or

Driven plate Replace the driven plate
unevenly worn

Insufficient grease on the

NG Clean and grease the splined
spline contact surface of the
contact surface
splined hub

Clean or repair the top gear

NG Corrosion or step wear on the shaft spline
top gear shaft spline Replace the top gear shaft

OK

NG Replace the pressure plate

Pressure plate Pressure plate unevenly worn
assembly

OK

Continued on the next page

 CLUTCH 7C-29

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG
Flywheel Flywheel unevenly worn Repair or replace the flywheel

OK

Crankshaft pilot bearing NG Top gear shaft wobble is

Replace the pilot bearing
causing pilot bearing wear
7C-30 CLUTCH

3. CLUTCH SHUDDER

Checkpoint Trouble Cause Countermeasure

Poorly connected components Tighten the connections

NG
Power train causing looseness and Repair or replace the
abrasion applicable parts

OK

NG Replace the pressure plate

Pressure plate Pressure plate unevenly worn
assembly

OK

Grease or oil adhering to the NG Clean the related parts and/or

Too much grease
facing replace the facing

Clean the related parts and/or

NG Defective transmission front replace the facing
cover oil seal Replace the transmission front
cover oil seal

Clean the related parts and/or

NG Defective crankshaft rear oil replace the facing
seal Replace the crankshaft rear oil
seal
OK

Insufficient grease on the

NG spline contact surface of the Clean and grease the spline
Driven plate
splined hub contact surface

Clean or repair the top gear

NG Corrosion or step wear on the shaft spline
top gear shaft spline Replace the top gear shaft

OK

Continued on the next page

 CLUTCH 7C-31

Checkpoint Trouble Cause Countermeasure

Continued from the previous page

OK

NG Replace the driven plate

Driven plate Loose facing rivets
assembly

NG Replace the driven plate

Warpage and/or uneven wear
assembly

OK

Flywheel NG Flywheel uneven wear Repair or replace the flywheel

7C-32 CLUTCH

4. CLUTCH NOISE
1) Clutch Pedal Depressed (Clutch Disengaged)

Checkpoint Trouble Cause Countermeasure

NG Insufficient grease at the Clean and grease the pedal

Pedal shaft and sleeve
pedal shaft and sleeve shaft and sleeve

NG Worn pedal shaft and/or Replace the pedal shaft with

sleeve the sleeve

OK

Insufficient grease at the Clean and grease the master

Master cylinder piston and NG maser cylinder piston and cylinder piston and push rod
push rod contact faces
push rod contact faces contact faces

OK

Driven plate NG Loose or broken damper Replace the driven plate

spring assembly

OK

Insufficient grease at the

Crankshaft pilot bearing NG Replace the crankshaft pilot
crankshaft pilot bearing (pilot
bearing
bearing worn)

2) Clutch Pedal Not Depressed (Clutch Engaged)

Driven plate damper spring NG Weak or broken damper

Replace the driven plate
spring

OK

Insufficient grease at the

NG Replace the crankshaft pilot
Crankshaft pilot bearing crankshaft pilot bearing (pilot
bearing
bearing worn)
 CLUTCH 7C-33

5. OIL LEAKAGE

Checkpoint Trouble Cause Countermeasure

Master cylinder NG Weak or damaged piston cap Replace the piston cap

OK

Master cylinder fluid pipe and NG Loosely connected fluid pipe Tighten the fluid pipe and/or
hose and/or hose hose connections

OK

NG
Slave cylinder Weak or damaged piston cup Replace the piston cup

OK

NG
Slave cylinder oil pipe Loosely connected oil pipe Tighten the oil pipe connection

OK

NG
Fluid reservoir Loosely connected oil pipe Tighten the oil pipe
7C-34 CLUTCH

SPECIAL SERVICE TOOL

ITEM NO. ILLUSTRATION PART NO. PART NAME

5-8525-3001-0
CLL-1 (J-24547) Clutch pilot aligner
 TBCLU-WE-0065 IN

You are requested to order this manual using the

manual number that is shown above.

This manual is applicable for vehicles in Indonesia.

All rights reserved, This manual may not be

reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.

Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT

Tokyo, Japan

First edition June, 2000

No. TBCLU-WE-0065 IN