clutch ISUZU TFS SERIES 1997 User Guide

4C1-68 FRONT WHEEL DRIVE
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found
through inspection.
For inspection and servicing of disc caliper, and relative parts, refer to Section 5 “Service Brakes”.
Hub
Hub bearing, oil seal
Knuckle spindle
Disc
Caliper
Free wheeling hub parts
(Option)
Clutch, knob, follower, inner, ring and
spring
Visual Check
Check the following parts for wear, damage or other abnormal
conditions.

FRONT WHEEL DRIVE 4C1-69
REASSEMBLY
Reassembly Steps
1. Spacer
2. Ring
3. Snap ring
4. Inner assembly
5. Snap ring
6. X-ring
7. Detent ball and spring
8. Knob
9. Snap ring
10. Retaining spring
11. Follower
12. Compression spring
13. Clutch assembly
14. Outer bearing
15. Inner bearing
16. Oil seal
17. Hub and disc assembly
18. Hub nut
19. Lock washer
20. Body assembly
21. Snap ring and shims
22. Cover assembly
23. Bolt

4C1-70 FRONT WHEEL DRIVE
Important Operations
1. Spacer
Apply grease to both faces of spacer.
4. Inner Assembly
Apply grease wheel bearing to inside face of ring.
g(oz)
Amount of grease 3 (0.10)
8. Knob
(1) Apply grease W heel bearing to outer circumference of knob
and inner circumference of cover.
(2) Align detent ball to either groove of cover.
9. Snap Ring
Turn the smoother face to knob side.
10.Retaining Spring
Align the end of spring to the end of cut portion of clutch spring
groove.
11.Follower
Install follower to clutch so that follower nail will come closer to
the bent portion of retaining spring by aligning follower stopper
nail to outer teeth of clutch. Then, hook retaining spring onto
upper portion of hanger nails of follower.
12.Compression Spring
Turn the smaller diameter side to follower.
13.Clutch Assembly
Align follower nail to handle groove, and then assemble clutch
with knob by pushing and turning clutch counterclockwise to
knob.

4C1-88 FRONT WHEEL DRIVE
(3) NOISES IN AUTOMATIC LOCKING FREE WHEEL HUB
Note :
Some noise at the time of shifting from
“LOCK” to “FREE” or vice versa is normal.
It is not a sign of trouble.
Checkpoint Trouble Cause Countermeasure
Operating of automatic locking
free wheel hubReplace the driven clutchOne side operating
Connect the axial play or
replace the driven clutchExcessive axial play
NG NG
OKHoldout ring axial play
Front axle or jointReplace or tightenDamaged or loose NG OK

WORKSHOP MANUAL
TF SERIES
CLUTCH
SECTION 7C

CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[ 7C- 2
General Description......................................................................................................... 7C-3
Torque Specification ...........................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-8
Servicing<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...... 7C- 13
Clut<0046004b0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[........ 7C- 15
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 7C- 15
Inspection and Repair................................................................................................. 7C- 20
Clutch Control .................................................................................................................. 7C- 27
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 7C- 27
Master Cylinder (Except 6VD1 Engine) .......................................................................... 7C- 30
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-30
Inspection and Repair................................................................................................. 7C- 31
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-32
Master Cylinder (6VD1 LHD Model) ................................................................................ 7C- 33
Disassembly and Reassembly ................................................................................... 7C- 33
Slave Cylinder (Except 6VD1 Engine) ............................................................................ 7C- 35
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-35
Inspection and Repair................................................................................................. 7C- 36
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-36
Hydraulic Damper Cylinder (Except 6VD1 Engine) ....................................................... 7C- 40
Inspection and Repair................................................................................................. 7C- 40
Troubleshooting .............................................................................................................. 7
C- 41
Special Service Tool ........................................................................................................ 7C-50
INDEX

7C-2 CLUTCH
MAIN DATA AND SPECIFICATIONS
ENGINEHEC Engine
Series with
MSG4JA1HEC Engine
Series with
MUA4JB1T 4JG2T 6VD1
Type Dry single plate with diaphragm
Size mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Clamping force kg(lb) 500 (1103) 500 (1103) 560 (1235) 640 (1411) 735 (1621)
(N) (4903) (4903) (5492) (6276) (7208)
Pressure plate
Outside diameter mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Inside diameter mm(in) 150 (5.906) 154 (6.063) 160 (6.299) 160 (6.299) 170 (6.70)
Driven plate
Thickness mm(in)
at free 8.4 (0.331) 8.6 (0.339) 8.0 (0.315) 8.2 (0.323) 8.3 (0.327)
at compressed 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 8.0 (0.315)
CLUTCH CONTROL LHD RHD
Type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Pedal height mm(in)
4JG2T 185.5-195.5 (7.30-7.70)
Others 178-188 (7.01-7.40) 216-226 (8.50-8.90)
Master cylinder
BoreStroke mm(in) 15.8735 (0.6251.38)
Slave cylinder
BoreStroke mm(in)
HEC Engine Series for
LHD/4JA120.6416 (0.8130.63)
HEC Engine Series for
RHD/4JB1T/4JG2T22.2215 (0.8750.59)
6VD1 22.2217 (0.8750.67)

CLUTCH 7C-3
GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE
HEC Engine Series4J Engine Series
6VD1
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 shift block through the clutch shaft and the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
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 shift block.
The shift block forces the release bearing against 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.
Except 6VD1 (3.2L) engine model, the conventional push-type clutch is used.
For 6VD1 (3.2L) engine model, the pull-type clutch is employed. The pull-type clutch is disengaged by pulling the
release lever (release bearing) to disengage the pressure plate.

7C-4 CLUTCH
MASTER CYLINDER
6VD1 LHD Model Except 6VD1 LHD Model
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-5
SLAVE CYLINDER
MUA Series
MSG Series
4J Engine Series
6VD1 Engine Series
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.