21
21
CLUTCH
CONTENTS
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 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.
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)
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
<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
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
13 ± 2 N×m
7
8
3
4
6
1
6 2
9
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
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
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.
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).