clutch ISUZU TF SERIES 2004 User Guide

5A-42 BRAKE CONTROL SYSTEM

Braking Sound (From EHCU) Is Heard While Not Braking

Step Action Value(s) Yes No
1 Is this the first vehicle start after engine start?
- It is self
checking
sound
Normal. Go to Step 2
2 Is vehicle speed under 10 km/h?
- It is self
checking
sound
Normal. Go to Step 3
3 Check for the following condition:
 At the time of shift down or clutch operation.
 At the time of low road friction drive (ice or snow
road) or rough road drive.
 At the time of high-speed turn.
 At the time of passing curb.
 At the time of operating electrical equipment
switches.
 At the time of racing the engine.
Did it occur under any one condition above?
- ABS may
sometimes be
actuated even
when brake
pedal is not
applied. Go to Step 4
4 Is there play in each or any sensor/wheel speed
sensor rotor?
- Repair.
Go to Step 7 Go to Step 5
5 Damage or powdered iron sticking to each or any
sensor/wheel speed sensor rotor?
- Repair.
Go to Step 7 Go to Step 6
6 Is each sensor normal?
Note : Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2WD or 4WD Model)

- Check
harness/
connector for
suspected
disconnection
If no
disconnection
is found,
replace EHCU
Go to Step 7 Repair.
Go to Step 7
7 Reconnect all components, ensure all components
are properly mounted.
Was this step finished?
- Repeat the
“Basic
diagnostic
flow chart” Go to Step 7

WORKSHOP MANUAL

TF SERIES




CLUTCH






SECTION 7C

CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 7C- 2
General Description......................................................................................................... 7C- 3
Torque Specification ....................................................................................................... 7C-15
Servicing........................................................................................................................... 7C-19
Clutch................................................................................................................................ 7C-21
Removal and Installation ............................................................................................ 7C-21
Inspection and Repair................................................................................................. 7C-26
Clutch Control .................................................................................................................. 7C-32
Removal and Installation ............................................................................................ 7C-32
Master Cylinder ................................................................................................................ 7C-33
Disassembly ................................................................................................................ 7C-33
Reassembly ................................................................................................................. 7C-34
Slave Cylinder (4J, C24SE) ............................................................................................. 7C-35
Disassembly ................................................................................................................ 7C-35
Inspection and Repair................................................................................................. 7C-36
Reassembly ................................................................................................................. 7C-37
Slave Cylinder (6VE1) ...................................................................................................... 7C-38
Disassembly ................................................................................................................ 7C-38
Inspection and Repair................................................................................................. 7C-39
Reassembly ................................................................................................................. 7C-40
Hydraulic Damper Cylinder ............................................................................................. 7C-41
Inspection and Repair................................................................................................. 7C-41
Troubleshooting .............................................................................................................. 7C-42
Special Service Tool ........................................................................................................ 7C-51

7C-2 CLUTCH
MAIN DATA AND SPECIFICATIONS
ENGINE 6VE1
4JA1-T(L) 4JA1-TC
4JH1-TC C24SE
Clutch type Dry single plate with diaphragm
Size mm (in)260 (10.24) 225 (8.86) 250 (9.84) 240 (9.45)
Clamping force kg(lb)735 (1621) 500 (1103) 640 (1411) 560 (1235)
(N)(7200) (4900) (6300) (5500)
Pressure plate
Outside diameter mm(in)260 (10.24) 225 (8.86) 250 (9.84) 240 (9.45)
Inside diameter mm(in)170 (6.69) 150 (5.906) 160 (6.299) 160 (6.299)
Driven plate
Thickness mm(in)
at free 8.8 (0.346) 8.4 (0.331) 8.3 (0.327) 8.7 (0.342)
at compressed 8.2 (0.323) 7.8 (0.307) 7.8 (0.307) 8.0 (0.315)
Clutch Cont. type Hydraulic
Pedal free play mm(in)5.0-15.0 (0.2-0.6)
Master cylinder
Bore

Stroke mm(in)15.87

35 (0.625

1.38)
Slave cylinder
Bore

Stroke mm(in)22.22

18.9
(0.875

0.744) 19.05

23
(0.749

0.906) 20.64

23
(0.813

0.906) 19.05

23
(0.749

0.906)

CLUTCH 7C-3
GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE
PUSH TYPE CLUTCH (4J C24SE)



PULL TYPE CLUTCH (6VE1)
A07RW046

7C-4 CLUTCH
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 release bearing through the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
For 4J series engine and HEC engine models, the push-type clutch is used.
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 release bearing.
The release bearing forces 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.
For 6VE1 engine model, the pull-type clutch is used. The pull-type clutch is disengaged by pulling the release lever
(release bearing) to disengage the pressure plate.

CLUTCH 7C-5
MASTER CYLINDER
C24SE/RHD

RTW47CSF000501

C24SE, 4J/LHD

RTW47CSF000201

7C-6 CLUTCH
6VE1/LHD

RTW47CSF000101

6VE1, 4J/RHD

RTW47CSF000401
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.

CLUTCH 7C-7
SLAVE CYLINDER
6VE1
A07RS005
4J

C24SE

RTW47CSF000301
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.

7C-8 CLUTCH
HYDRAULIC DAMPER CYLINDER


RTW47CLF000101-X

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