ISUZU KB P190 2007 Workshop Repair Manual

CLUTCH 7C-43
1. CLUTCH SLIPPAGE

Checkpoint Problem Countermeasure


Adjust the push rod play

No push rod play in the master
cylinder

NG
Clutch pedal free play

Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal

Clean the related parts and/or
replace the facing


Repair or replace the
transmission front cover


Defective transmission front
cover oil seal

Continued on the next page

Grease or oil adhering to the
facing

Too much grease


Transmission front cover
unevenly worn


Release bearing

NG
NG
NG
OK
OK OK


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ISUZU KB P190 2007

7C-44 CLUTCH
Checkpoint Problem Countermeasure

Replace the release bearingRelease bearing broken
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Defective crankshaft rear oil
seal
NG
NG
OK
OKGrease or oil adhering to the
facing
Clutch diaphragm springReplace the clutch pressure
plate assemblyW eak or broken clutch
diaphragm spring
Replace the driven plate
assemblyWorn facing
NG
NG
OKFacing
Continued from the previous page



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ISUZU KB P190 2007

CLUTCH 7C-45
2. CLUTCH DOES NOT RELEASE PROPERLY

Checkpoint Problem Countermeasure


Adjust the push rod play

Too much push rod play in the
master cylinder

NG
Clutch pedal free play

Driven plate

Replace the driven plate

Driven plate warped or
unevenly worn


Hydraulic circuit

Bleed the hydraulic circuit

Air in the hydraulic circuit

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


Pressure plate

Replace the pressure plate
assembly


Clean and grease the splined
contact surface


Pressure plate unevenly worn

Insufficient grease on the
spline contact surface of the
splined hub
OK NG
NG
NG
OK
Continued on the next page


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ISUZU KB P190 2007

7C-46 CLUTCH
Checkpoint Problem Countermeasure

Crankshaft pilot bearingReplace the pilot bearingTop gear shaft wobble is
causing pilot bearing wear
Repair or replace the flywheelFlywheel unevenly worn
NG
NG
OK
OKFlywheel
Continued from the previous page


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ISUZU KB P190 2007

CLUTCH 7C-47
3. CLUTCH SHUDDER

Checkpoint Problem Countermeasure

Grease or oil adhering to the
facing
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Replace the pressure plate
assembly
Defective transmission front
cover oil seal
Pressure plate unevenly wornPressure plate
Clean the related parts and/or
replace the facing
Tighten the connections
Repair or replace the
applicable parts
Too much grease
Poorly connected components
causing looseness and
abrasion
OK
NG
NG
NG
NG
OK
Power train
Clean and grease the spline
contact surface
Insufficient grease on the
spline contact surface of the
splined hub
Driven plate
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Corrosion or step wear on the
top gear shaft spline
Defective crankshaft rear oil
seal
OK NG
NG
NG
OK
Continued on the next page

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ISUZU KB P190 2007

7C-48 CLUTCH
Checkpoint Problem Countermeasure

Replace the driven plate
assemblyW arpage and/or uneven wear
Replace the driven plate
assemblyLoose facing rivets
NG
NG
OKDriven plate
Continued from the previous page
FlywheelRepair or replace the flywheelFlywheel uneven wear
NG
OK


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ISUZU KB P190 2007

CLUTCH 7C-49
4. CLUTCH NOISE

1) Clutch Pedal Depressed (Clutch Disengaged)

Checkpoint Problem Countermeasure

Replace the pedal shaft with
the sleeveW orn pedal shaft and/or
sleeve
Clean and grease the pedal
shaft and sleeveInsufficient grease at the
pedal shaft and sleeve
NG
NGPedal shaft and sleeve
Master cylinder piston and
push rod contact facesClean and grease the master
cylinder piston and push rod
contact facesInsufficient grease at the
maser cylinder piston and
push rod contact faces
NG
OK
Driven plateReplace the driven plate
assemblyLoose or broken damper
spring
NG
OK
Crankshaft pilot bearingReplace the crankshaft pilot
bearingInsufficient grease at the
crankshaft pilot bearing (pilot
bearing worn)
NG
OK



2) Clutch Pedal Not Depressed (Clutch Engaged)

Replace the driven plateW eak or broken damper
spring
NGDriven plate damper spring
Replace the crankshaft pilot
bearingInsufficient grease at the
crankshaft pilot bearing (pilot
bearing worn)
OK
NG
Crankshaft pilot bearing

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ISUZU KB P190 2007

7C-50 CLUTCH
5. OIL LEAKAGE

Checkpoint Problem Countermeasure


Replace the body sub
assembly
W eak or damaged piston cup

NG


Tighten the oil pipe


Tighten the oil pipe connection


Tighten the fluid pipe and/or
hose connections


Fluid reservoir

Loosely connected oil pipe


Loosely connected oil pipe


Master cylinder fluid pipe and
hose

Loosely connected fluid pipe
and/or hose


Slave cylinder oil pipe


Replace the piston cup

Slave cylinder

W eak or damaged piston cup

NG
NG
NG
NG
OK
OK
OK
OK

Master cylinder





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ISUZU KB P190 2007

CLUTCH 7C-51
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME


5-8525-3001-0 (J-24547)

Clutch pilot aligner



5-8840-2000-0 (J-5822)

Pilot bearing remover



5-8840-0019-0 (J-23907)

Sliding hammer



5-8840-0125-0 (J-26516-A)

Pilot bearing installer



5-8840-0007-0 (J-8092)

Drive handle




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ISUZU KB P190 2007

Section 7D Transfer House ............................................................................................ 4879 PAGE
Section 7D1 Transfer Control System.......................................................................... 4923
SECTION 7
TRANSFER CASE
TA BLE OF CONTENTS
TRANSMISSION

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ISUZU KB P190 2007