CLUTCH

Click on the applicable bookmark to selected the required model year.

 21-1

CLUTCH
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Clutch Pedal Position Switch

Continuty Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2 CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5

Clutch Pedal Inspection and Adjustment . . . . . . . 2 Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 8
21-2 CLUTCH - General Information/Service Specifications/Lubricants/On-vehicle Service

GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
Items Standard value
Clutch pedal height mm 202 - 205 <L.H. drive vehicles>
197 - 200 <R.H. drive vehicles>
Clutch pedal clevis pin play mm 1- 3
Clutch pedal free play mm 6 - 13
Distance between the clutch pedal and the toeboard 75 or more <L.H. drive vehicles>
when the clutch is disengaged mm 70 or more <R.H. drive vehicles>

LUBRICANTS
Items Specified lubricants Quantity
Clutch fluid Brake fluid DOT3 or DOT4 As required
Push rod assembly Rubber grease
Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011

Clutch pedal height ON-VEHICLE SERVICE

CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height.
Standard value (A):
A
202 - 205 mm <L.H. drive vehicles>
197 - 200 mm <R.H. drive vehicles>

Clutch pedal 3. If the height of the clutch pedal is outside the standard
position switch value, loosen the setting nut or clutch pedal position switch
lock nut <vehicles with auto-cruise control> to adjust the
Setting nut pedal height to the standard value.

Lock nut

12 ± 3 N×m
 CLUTCH - On-vehicle Service 21-3
Clutch pedal clevis pin play 4. Measure the clutch pedal clevice pin play.
Standard value (B): 1 - 3 mm
5. If the clutch pedal play is not within the standard value,
loosen the setting nut to adjust the play to the standard
value.
Caution
Do not push in the master cylinder push rod at this
B
time, otherwise the clutch will not operate properly.

Clutch pedal free Distance between the 6. After completing the adjustments, confirm that the clutch
play clutch pedal and the pedal free play (measured at the face of the pedal pad)
toeboard when the
clutch is disengaged and the distance between the clutch pedal (the face of
the pedal pad) and the toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6 - 13 mm
Standard value (D):
C D 75 mm or more <L.H. drive vehicles>
70 mm or more <R.H. drive vehicles>
7. If the clutch pedal free play and the distance between
the clutch pedal and the toeboard when the clutch is
disengaged do not agree with the standard values, it
is probably the result of either air in the hydraulic system
or a faulty master cylinder, release cylinder or clutch.
Bleed the air, or disassemble and inspect the master
cylinder, release cylinder or clutch.
8. Turn back the carpet, etc.

CLUTCH PEDAL POSITION SWITCH

CONTINUITY CHECK
1. Adjust the clutch pedal. (Refer to P.21-2.)
2. Depress the clutch pedal, and check the continuity
No continuity Continuity between the terminals.
Measurement Conditions Terminal No. Terminal No.
1 2
4 mm Clutch pedal depressed
Clutch pedal not depressed

BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
21-4 CLUTCH - Clutch Pedal

CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21-2)

<R.H. drive vehicles>

<L.H. drive vehicles>

4
13 ± 2 N×m
3

12 ± 2 N×m

5
4 1
13 ± 2 N×m 3 2
7

6
12 ± 2 N×m
5
2 1

Removal steps
D Stay A (Refer to GROUP 52A - 3. Clevis pin
Instrument Panel) 4. Clutch master cylinder mounting nut
1. Clutch pedal position switch 5. Master cylinder member mounting bolt
<vehicles with auto-cruise control> 6. Pedal pad
2. Snap pin 7. Clutch pedal assembly
 CLUTCH - Clutch Control 21-5
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Clutch Fluid Draining D Clutch Fluid Supplying
D Clutch Line Bleeding (Refer to P.21-3)
D Clutch Pedal Adjustment (Refer to P.21-2)

<6G74>
<R.H. drive vehicles>
2 1
3
4 <L.H. drive vehicles>

3 1

13 ± 2 N×m
7
13 ± 2 N×m

18 ± 2 N×m
7
9 8
7
22 ± 4 N×m

Release fork
Release cylinder 5 23 ± 2 N×m
push rod

6
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011 6

Clutch master cylinder assembly Clutch release cylinder assembly

removal steps removal steps
1. Clevis pin 5. Clutch hose connection
2. Clutch tube connection 6. Clutch release cylinder assembly
3. Clutch master cylinder assembly Clutch line removal steps
4. Sealer
7. Clutch tube
8. Bracket
9. Clutch hose
21-6 CLUTCH - Clutch Control

<4D56>
<R.H. drive vehicles>
1
2
3
<L.H. drive vehicles>
4

3 1

13 ± 2 N×m

13 ± 2 N×m

7 2

7
18 ± 2 N×m
35 ± 6 N×m

23 ± 2 N×m
7
8

Release fork
Release cylinder
push rod

6 5
6
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011

Clutch master cylinder assembly Clutch release cylinder assembly

removal steps removal steps
1. Clevis pin 5. Clutch hose connection
2. Clutch tube connection 6. Clutch release cylinder assembly
3. Clutch master cylinder assembly Clutch line removal steps
4. Sealer
7. Clutch tube
8. Clutch hose
 CLUTCH - Clutch Control 21-7
<4M41>
<R.H. drive vehicles>
3 1
2
4 <L.H. drive vehicles>

3 1

13 ± 2 N×m

10 13 ± 2 N×m
2

11 10
48 ± 6 N×m

9 19 ± 3 N×m
12

8
22 ± 2 N×m

23 ± 2 N×m

7
25 ± 5 N×m

5
6

Release fork
Release cylinder
push rod

15 ± 1 N×m 18 ± 2 N×m

6
Specified grease:
MITSUBISHI genuine 11 10
grease Part No. 0101011

Clutch master cylinder assembly Clutch chamber assembly removal

removal steps steps
1. Clevis pin 7. Union
2. Clutch tube connection 8. Clutch hose connection
3. Clutch master cylinder assembly 9. Clutch chamber assembly
4. Sealer Clutch line removal steps
Clutch release cylinder assembly 10. Clutch tube
removal steps 11. Clutch tube
5. Union 12. Clutch hose
6. Clutch release cylinder assembly
21-8 CLUTCH - Clutch Control

DISASSEMBLY AND REASSEMBLY

CLUTCH MASTER CYLINDER
Caution
Do not disassemble piston assembly.
5

13 ± 2 N×m
7

8
3

4
6
1

6 2
9

<L.H. drive vehicles> 9

<R.H. drive vehicles>

2

4 2
1
2

3
4
Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease

Disassembly steps
1. Piston stopper ring 6. Spring pin
2. Piston assembly 7. Reservoir tank
"AA 3. Push rod assembly 8. Seal
4. Boot 9. Master cylinder body
5. Reservoir cap

INSTALLATION SERVICE POINT

"AA PUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of clutch pedal easier.

121 ± 1 mm
 Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
 SERVICE BULLETIN
SERVICE PUBLICATION & TRAINING
INTERNATIONAL AFTER-SALES DEPARTMENT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN No.: MSB-02E21-001

Date: 2002-08-16 <Model> <M/Y>

Subject: ADDITION OF PROCEDURE FOR BLEEDING (EC)L300(P00) 95-05
CLUTCH RELEASE CYLINDER (EC)PAJERO
SPORT/MONTERO
SPORT
(P80W, P90W)
Group: CLUTCH Draft No.: 02AL019 (EC)L200(K60-70)
(EC)PAJERO
PININ/MONTERO
iO(H60-70)
(EC)L400(PA0-PD0)
INFORMATION INTERNATIONAL
AFTER-SALES (EC)PAJERO/
DEPARTMENT T.Inoue - Manager
MONTERO(V60-70)
SERVICE PUBLICATION & TRAINING

1. Description:
This Service Bulletin informs you of the additions that have been made to the Workshop Manuals
listed below in connection with the procedure for bleeding the clutch release cylinder.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
’95 L300 Workshop Manual PWWE9404 (English) 21-4
PWWG9405 (German)
’99 PAJERO SPORT Workshop Manual PWJE9812 (English) 21-3
’99 MONTERO SPORT Workshop Manual PWJS9813 (Spanish)
’99 PAJERO SPORT Workshop Manual PWJF9814 (French)
PWJG9815 (German)
’02 PAJERO SPORT/MONTERO SPORT PWJT9818R-C (English) -
Workshop Manual CD-ROM PWJT9818R-C (Spanish)
PWJT9818R-C (French)
PWJT9818R-C (German)
’97 L200 Workshop Manual PWTE96E1 (English) 21-3
PWTS96E1 (Spanish)
PWTF96E1 (French)
PWTG96E1 (German)
’00 PAJERO PININ Workshop Manual CKRE00E1 (English) 21-3
’00 MONTERO iO Workshop Manual CKRS00E1 (Spanish)
’00 PAJERO PININ Workshop Manual CKRF00E1 (French)
CKRG00E1 (German)
CKRD00E1 (Dutch)
’00 PAJERO PININ/MONTERO iO CKRX00E1CD (English) -
Workshop Manual CD-ROM CKRX00E1CD (Spanish)
’00 PAJERO PININ Workshop Manual CKRZ00E1CD (French) -
CD-ROM CKRZ00E1CD (German)
CKRZ00E1CD (Dutch)
CKRZ00E1CD (Italian)
’95 L400 Workshop Manual PWWE9410 (English) 21-8
PWWS9411 (Spanish)
PWWF9412 (French)
PWWG9413 (German)
PWWD9414 (Dutch)
PWWW9415 (Swedish)
’01 PAJERO Workshop Manual Vol.1 PWJE0001(1/2) (English) 21-3
’01 MONTERO Workshop Manual Vol.1 PWJS0002(1/2) (Spanish)
’02 PAJERO/MONTERO Workshop Manual PWJT0008R-B (English) -
CD-ROM PWJT0008R-B (Spanish)
PWJT0008R-B (French)
PWJT0008R-B (German)
’95 L300 Workshop Manual Vol.1 PWWE9409(1/2) (English) 21-7
PWWF9420(1/2) (French)

2
’01 PAJERO Workshop Manual Vol.1
CLUTCH– On-vehicle Service 21-3
Clutch pedal clevis pin play 4. Measure the clutch pedal clevis pin play.
Standard value (B): 1 – 3 mm
5. If the clutch pedal play is not within the standard value, loosen
the setting nut to adjust the play to the standard value.
Caution
Do not push in the master cylinder push rod at this time,
otherwise the clutch will not operate properly.
A14W0002

Clutch pedal free Distance between 6. After completing the adjustments, confirm that the clutch pedal
play the clutch pedal
and the toeboard free play (measured at the face of the pedal pad) and the
when the clutch is distance between the clutch pedal (the face of the pedal pad)
disengaged and the toeboard when the clutch is disengaged are within the
standard value ranges.
Standard value (C): 6-13 mm
Standard value (D):
75 mm or more <L.H. drive vehicles>
70 mm or more <R.H. drive vehicles>
7. If the clutch pedal free play and the distance between the clutch
14W0003
14W0002
00005683 pedal and the toeboard when the clutch is disengaged do not
agree with the standard values, it is probably the result of either
air in the hydraulic system or a faulty master cylinder or clutch.
Bleed the air, or disassemble and inspect the master cylinder or
clutch.
8. Turn back the carpet, etc.

CLUTCH PEDAL POSITION SWITCH CONTINUITY

CHECK
1. Adjust the clutch pedal. (Refer to P.21- 2.)
2. Depress the clutch pedal, and check the continuity between the
No continuity Continuity terminals.

Measurement Conditions Terminal No. Terminal No.

1 2
4 mm Clutch pedal depressed { {
AX0014BN
Clutch pedal not depressed

BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture of the
specified fluid and other fluid.
<Added>
NOTE
If the clutch pedal feels spongy when depressed, the clutch release cylinder may have
air trapped inside and should be bled of the air. When bleeding the cylinder, jack up the
front of the vehicle (with a release cylinder having the breather at its front end) or the
rear of the vehicle (with a cylinder having the breather at its rear end).