ISUZU TF SERIES 2004 Workshop Manual

CLUTCH 7C-39
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.


206RS003
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.
206RS004
Piston and Piston Cup
1. Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
2. Replace the inner parts with new parts shown in the
illustration.
206RS005

3. Measure the clearance between slave cylinder wall and
piston.
4. If the measured value exceeds the specified limit, the slave
cylinder assembly must be replaced.
mm(in)

Standard Limit
0.07 (0.0028) 0.15 (0.006)

7C-40 CLUTCH
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:


206RS006
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the fron
t
of cylinder. Use care so as not to scratch the cylinder.

CLUTCH 7C-41
HYDRAULIC DAMPER CYLINDER
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




Visually check for oil leakage and other damage.
If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.

7C-42 CLUTCH

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage

CLUTCH 7C-43

1. CLUTCH SLIPPAGE

Checkpoint
Trouble Cause
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


Clean and grease the release
bearing

Release bearing

Insufficient grease on the front
cover contact surfaces

NG NG NG NG OK
OK
OK

7C-44 CLUTCH

Checkpoint Trouble Cause 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 assemblyWeak or broken clutch
diaphragm spring
Replace the driven plate
assemblyWorn facing
NG NG
OKFacing Continued from the previous page

CLUTCH 7C-45

2. CLUTCH DOES NOT RELEASE PROPERLY

Checkpoint Trouble Cause
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

7C-46 CLUTCH

Checkpoint Trouble Cause 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

CLUTCH 7C-47

3. CLUTCH SHUDDER

Checkpoint
Trouble Cause
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
OKNG NG NG
OK
Continued on the next page

7C-48 CLUTCH

Checkpoint Trouble Cause Countermeasure

Replace the driven plate
assemblyWarpage 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