CLUTCH SYSTEM

CLUTCH UNIT (AIR SERVO TYPE)

 CLUTCH UNIT
(AIR SERVO TYPE)

CONTENTS
SERVICE DATA ........................................... CL-1- 1 CONSTRUCTION ........................................ CL-3- 1
SPECIFICATIONS ........................................ CL-1- 1 DISASSEMBLY ............................................ CL-3- 2
SERVICE DATA ........................................... CL-1- 1 INSPECTION ............................................... CL-3- 4
TIGHTENING TORQUE ............................... CL-1- 2 REASSEMBLY ............................................. CL-3- 6
TOOLS ........................................................... CL-2- 1 PERFORMANCE TEST ............................... CL-3- 6
CLUTCH BOOSTER .................................. CL-3- 1

SUPPLEMENTAL OUTLINE
+ Addition of a unit due to introduction of a new vehicle model
 SERVICE DATA CLUTCH UNIT (AIR)

SERVICE DATA
SPECIFICATIONS
CLUTCH BOOSTER
Unit: mm (in)
*Unit name 04541 05330
04558 04622
Item 04542 05331
Type Air-servo
Power cylinder (cylinder shell) I.D. 90.0 (3.543) 105.0 (4.134)
Power piston stroke 35.8 (1.409)
Cylinder body (hydraulic cylinder) I.D. 19.05 (0.7500) 19.8 (0.780) 19.05 (0.7500)
Liquid pressure side 16.0 (0.630) 12.7 (5.000) 16.0 (0.630)
Relay piston O.D.
Atmospheric side 23.5 (0.925) 27.0 (1.063) 23.5 (0.925)
Relay piston stroke 3.6 (0.142)
Push rod O.D. 8.0 (0.315)

* Identification of the clutch booster unit

The unit can be clearly identified by the number stamped on the power cylinder name plate.
Ex. 642-04542 (Refer to unit name 04542.)

SERVICE DATA
CLUTCH BOOSTER
Unit: mm (in)
Application
Maintenance
Item Service limit Remarks 04541, 04542 05330
standard
04558, 04622 05331
Clearance between power piston and
— 1.50 (0.0591) j j
cylinder shell
Clearance between hydraulic piston
— 0.08 (0.0031) j j
and hydraulic cylinder

Clearance be- Liquid pressure

— 0.11 (0.0043) j j
tween relay piston side
and cylinder body Atmospheric side — 0.30 (0.0118) j j
Bend of push rod — 0.15 (0.0059) j j

Piston return 86.8 (3.417) — j —

spring 112.4 (4.425) — — j

Relay piston return 30.1 (1.185) — j —

Free length
spring 23.8 (0.937) — — j
23.1 (0.909) — — j
Poppet spring
26.1 (1.027) — j —
When compressed to
— 66.69 {6.80, 14.99} j —
Piston return 59.9 mm (2.358 in)
spring When compressed to
— 99.96 {10.2, 22.48} — j
59.5 mm (2.342 in)
Tension
N {kgf, lbf} Relay piston return — 10.40 {1.06, 2.34} When compressed to j —
spring — 24.99 {2.55, 5.62} 13.1 mm (0.516 in) — j
— 2.25 {0.23, 0.507} When compressed to — j
Poppet spring
— 16.66 {1.70, 3.74} 14.85 mm (0.585 in) j —

CL-1-1
 SERVICE DATA CLUTCH UNIT (AIR)

TIGHTENING TORQUE
CLUTCH BOOSTER
Unit: N·m {kgfzm, ftzlbf}
Item Tightening torque Remarks
Cylinder body and cylinder shell assembling bolt and nut 20 - 29 {2.0 - 3.0, 14 - 22}
Upper valve body mounting bolt 4 - 6 {0.4 - 0.6, 2.9 - 4.3}
Connector 20 - 29 {2.0 - 3.0, 14 - 22}
Piston plate mounting nut 20 - 29 {2.0 - 3.0, 14 - 22}
Air bleeder screw 7 - 13 {0.7 - 1.3, 5.1 - 9.4}
Exhaust cover 15 - 20 {1.5 - 2.0, 11 - 14}
Push rod clevis nut 64 - 83 {6.5 - 8.5, 47 - 61} Unit name 04541 only
Elbow connector 15 - 167 {1.5 - 17.0, 11 - 123} Unit name 04558 only

CL-1-2
 TOOLS CLUTCH UNIT (AIR)

TOOLS
CLUTCH BOOSTER
* Tool numbers are designated by JIDOSHA KIKI CO., LTD.
Tool name and number
Description Shape
Liquid pressure side Atmospheric side

Cup diameter
910-23292 910-23293
19.8 mm (0.780 in) Used to
insert cup packing
into hydraulic
Cup diameter piston
910-23284 910-23285
19.05 mm (0.7500 in)
WCL024A
Cup packing
inserting guide
Cup diameter
910-24902 910-24905
16.0 mm (0.630 in)
Used to
insert cup packing
into relay piston
Cup diameter
910-24900 910-24903
12.7 mm (0.500 in)
WCL025A

CL-2-1
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

CLUTCH BOOSTER
CONSTRUCTION

WCL218A

CL-3-1
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

DISASSEMBLY
REMOVAL
Key point of removal
1. Turn the key switch to the ‘‘OFF’’ position and chock the wheels
to be safe.

2. Do not separate the wear indicator and stay.

WTM043A

3. Plug the tube and hose to prevent dirt or dust from entering.

CL-3-2
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

DISASSEMBLY

WCL045A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j1 Push rod assembly (Unit name j
15 Piston return spring j
29 Retainer
04541 only) j
16 Cylinder shell j
30 Cup packing
j2 Push rod assembly j
17 Collar j
31 Retainer assembly
j3 Guard j
18 O-ring j
32 Washer
j4 Connector j
19 Power piston assembly j
33 Retainer ring
j5 Gasket j
20 Nut j
34 Spring pin
j6 Poppet spring j
21 Washer
j
35 Elbow connector (Unit name 04558
j7 Poppet valve j only)
22 Push rod
j8 Upper valve body j
36 Exhaust cover
j
23 O-ring
j9 O-ring j
37 Air bleeder screw
j
24 Cup packing
j
10 Relay piston return spring j
38 Cylinder body
.j
25 Piston plate
j
11 O-ring j
39 Eyebolt
j
26 Hydraulic piston
j
12 Relay piston assembly j
40 Gasket
>j
27 Cup packing
>j
13 Cup packing j
41 Eye connector
j
14 O-ring
>j
28 Cup packing j
42 Gasket
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

CL-3-3
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

Key point of disassembly

j25 Piston plate
Be sure to use the socket when placing the piston assembly in a
vise.

CCL2016A

INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the service limit has been
exceeded, repair or replace faulty parts.

Clearance between power piston and cylinder shell

Unit: mm (in)
Maintenance standard Service limit
— 1.50 (0.0591)

WCL046A

Clearance between hydraulic piston and hydraulic cyl-

inder
Unit: mm (in)
Maintenance standard Service limit
— 0.08 (0.0031)

WCL047A

Clearance between relay piston and body

Unit: mm (in)
Item Maintenance standard Service limit
Liquid pressure side — 0.11 (0.0043)
Atmospheric side — 0.30 (0.0118)

WCL048A

CL-3-4
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

Bend of push rod

Unit: mm (in)
Maintenance standard Service limit
— 0.15 (0.0059)

WCL060A

Free length
Unit: mm (in)
Maintenance
Item Unit name Service limit
standard
04541, 04542
Piston return 86.8 (3.417) —
04558, 04622
spring
05330, 05331 112.4 (4.425) —
04541, 04542
Relay piston re- 30.1 (1.185) —
04558, 04622 CST2-053
turn spring
05330, 05331 23.8 (0.937) —
04541, 04542
26.1 (1.027) —
Poppet spring 04558, 04622
05330, 05331 23.1 (0.909) —

Tension
Unit: N {kgf, lbf}
Maintenance
Item Unit name Service limit Remarks
standard
04541, 04542 66.69 When compressed to
Piston —
04558, 04622 {6.80, 14.99} 59.9 mm (2.358 in)
return
spring 99.96 When compressed to
05330, 05331 —
{10.2, 22.48} 59.5 mm (2.342 in)

Relay 04541, 04542 10.40 CST2-054

—
piston 04558, 04622 {1.06, 2.34} When compressed to
return 24.99 13.1 mm (0.516 in)
spring 05330, 05331 —
{2.55, 5.62}
04541, 04542 16.66
—
Poppet 04558, 04622 {1.70, 3.74} When compressed to
spring 2.25 14.85 mm (0.585 in)
05330, 05331 —
{0.23, 0.507}

CL-3-5
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

REASSEMBLY
Key point of reassembly
j27 , j
28 Cup packing
Using the cup packing inserting guide, install the cup packings to
the hydraulic piston.
Pay attention to the installation position and direction as two cup
packings are not the same.
Cup packing inserting guide
Item
Liquid pressure side Atmospheric side WCL035A

Cup diameter
910-23292 910-23293
19.8 mm (0.780 in)
Cup diameter
910-23284 910-23285
19.05 mm (0.7500 in)

WCL050A

j13 Cup packing

Using the cup packing inserting guide, install the cup packing to the
relay piston assembly.
Cup packing inserting guide
Item
Liquid pressure side Atmospheric side
Cup diameter
910-24902 910-24905
16.0 mm (0.630 in)
Cup diameter
910-24900 910-24903
12.7 mm (0.500 in) WCL051A

PERFORMANCE TEST
AIR TIGHTNESS TEST
With the clutch booster attached to the vehicle, raise the air
pressure to 588 kPa {6 kgf/cm2, 85 psi} or more, then loosen the
plugs on the clutch booster exhaust pipe and cylinder shell bottom
to determine whether any compressed air leaks.

CL-3-6
 CLUTCH BOOSTER CLUTCH UNIT (AIR)

OIL TIGHTNESS TEST

Depress the clutch pedal, and determine whether oil leaks from the
joints of the hydraulic circuit. Keep the clutch pedal depressed to a
fixed position and determine whether the pedal resistance varies
greatly over time. Also check whether the clutch booster push rod
moves. If no abnormality is found, the piston cup and oil seal can
be considered normal.

OPERATION TEST
Depress the clutch pedal repeatedly and then check the movement
of the clutch booster push rod by listening to the noise of
compressed air being discharged from the exhaust pipe. The push
rod must move smoothly without any delay.

SINGLE BOOSTER TEST

The clutch booster can be examined closely by attaching the clutch
booster test kit to a brake booster tester.

PERFORMANCE CURVE (REFERENCE)

Some characteristic diagrams of the clutch booster are given for
reference as they differ somewhat depending on the booster.
The figures show when the stroke is 5 mm (0.20 in).

WCL151A

CL-3-7
CLUTCH BOOSTER CLUTCH UNIT (AIR)

WCL150A

WCL212A

CL-3-8