ISUZU KB P190 2007 Workshop Repair Manual

CLUTCH 7C-23


Important Operations - Removal
1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of section 7B and 7B1
for “REMOVAL AND INSTALLATION” procedure.


2. Pressure Plate Assembly
3. Driven Plate Assembly
(1) Use the clutch pilot aligner
1 to prevent the driven plate
assembly
2 from falling free.
Clutch Pilot Aligner : 5-8525-3001-0(J-24547)



4J series, C24SE (MSG, MUA)


(2) Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3) Remove the pressure plate assembly
3 from the flywheel.
(4) Remove the driven plate from the flywheel.


4JJ1 (High Output) (MUX)
RTW 77CSH000601

RTW 77CSH000801
4. Shift Fork (MUX)
5. Release Bearing (MUX)
(1) Remove the shift fork snap pin (2).
(2) Remove the shift fork pin and shift fork (3) from the fulcrum bridge.
(3) Remove the release bearing (1) from the transmission case.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7C-24 CLUTCH
015RW 053
6. Flywheel Assembly and Crank Bearing (MUX)
(1) Remove flywheel assembly and crankshaft bearing. Do not remove except for replacement.
(2) Use the remover 5-8840-2000-0 (J-5822) and sliding hammer 5-8840-0019-0 (J-23907) to remove the crankshaft
bearing



Important Operations - Installation
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.

015RW 054
6. Flywheel Assembly and Crank Bearing (MUX)
(1) Install flywheel assembly and crankshaft bearing. Use the installer 5-8840-0125-0 (J-26516-A) and driver handle 5-
8840-0007-0 (J-8092) to install the crankshaft bearing then
clean and lubricate with grease.
015RS047
(2) Install new flywheel fixing bolts in the order illustrated and tighten them to the specified torque. N⋅m (kg ⋅m/lb ⋅ft)
MUX 54 (5.5/40)
NOTE: Do not reuse the bolt and do not apply oil or thread lock
to the bolt.

RTW 77CSH000701
5. Release Bearing (MUX)
4. Shift Fork (MUX)
(1)
Apply molybdenum disulfide type grease to the pin hole
inner circumferences and thrust surfaces.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

CLUTCH 7C-25
201RW 012
(2) Apply molybdenum disulfide type grease to the areas shown in illustration.
(3) Install the release bearing to the transmission front cover.
(4) Install the shift fork to the fulcrum bridge and insert the pin from bottom of the fulcrum bridge.
(5) Install the washer and snap pin.





3. Driven plate Assembly
2. Pressure Plate Assembly
(1) Clean the flywheel surface.
(2) Clean the facing surface.
(3) Use the clutch pilot aligner
1 to install the driven plate
assembly
2 to the flywheel 3.
Clutch Pilot Aligner : 5-8525-3001-0(J-24547)


4 4J series, C24SE (MSG, MUA)

(4) Clean the pressure plate surfaces.
(5) Align the pressure plate assembly
4 with the flywheel
knock pin
5.
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the numerical order shown in the illustration.
Clutch Cover Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
18 ± 3 (1.8 ± 0.3 / 13.0 ± 2.2)


4JJ1 (High Output) (MUX)
RTW 77CSH000601


(8) Remove the clutch pilot aligner.
Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7C-26 CLUTCH
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




PRESSURE PLATE ASSEMBLY
Visually inspect the pressure plate friction surface for
excessive wear and heat cracks.
If excessive wear or deep heat cracks are present, the
pressure plate must be replaced.



Pressure Plate Warpage
Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the
pressure plate must be replaced.
Pressure Plate W arpage mm(in)
Limit
0.3 (0.012)



Clutch Cover
Visually inspect the entire clutch cover for excessive wear,
cracking , and other damage.
The clutch cover must be replaced if any of these conditions
are present.





1. Abrasion, scratches, cracks and deflection of friction face to
the disc, loose rivet and wear of ring
• Grind small scratches, or replace the assembly if extreme
scratches are found.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

CLUTCH 7C-27



RTW 67CSH000101


Clutch Set Force
1. Invert the pressure plate assembly.
2. Place a metal sheet “A” on the pressure plate.
3. Compress the pressure plate assembly until the distance “B” becomes specified.
Thickness and Distance mm(in
)

A B
4JJ1 (High Output)
(MUX) 8.3 (0.327) 12 (0.472)
4JA1-T (MSG) 7.8 (0.307) 20 (0.787)
4J series (MUA) 7.8 (0.307) 18 (0.709)
C24SE (MUA) 8.0 (0.315) 7.9 (0.311)
4. Note the pressure plate gauge reading.
Driven Plate Clamping Load N (kg/Ib)
Standard
4JJ1 (High Output) (MUX) 6860 (700/1544)
4JA1-T (MSG) 5070 (517/1140)
4J series (MUA) 6300 (642/1415)
C24SE (MUA) 5500 (561/1237)

RTW 37CSH000101
Diaphragm Spring Finger Height
1. Place a new driven plate or the appropriate spacer beneath
the pressure plate.
2. Fully compress the pressure plate and diaphragm spring. There are two ways to do this.
• Use a bench press to press down on the assembly from the
top.
• Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 - 98 N
(11 - 22 lb) in direction of release, when clutch cover assembly
is bolted to the flywheel.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7C-28 CLUTCH

3. Measure the spring height from base to spring tip "H". If the
measured value exceeds the specified limit, the pressure
plate assembly must be replaced.
Spacer Thickness mm(in)
A B
4JJ1 (High Output)
(MUX) 8.3 (0.327) 12 (0.472)
4JA1-T (MSG) 7.8 (0.307) 20 (0.787)
4J series (MUA) 7.8 (0.307) 18 (0.709)
C24SE (MUA) 8.0 (0.315) 7.9 (0.311)
Finger Height: H
4JJ1 (High Output) (MUX) 49.9-51.9 (1.96-2.04)
4JA1-T (MSG) 31-33 (1.22-1.30)
4J series (MUA) 39-41 (1.54-1.61)
C24SE (MUA) 39-41 (1.54-1.61)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

CLUTCH 7C-29

RTW 77CSH000301
Release Bearing (MUX)
1. Visually check the release bearing for excessive play, noiseand breakage.
2. If any of these conditions are discovered, the release bearing must be replaced.
3.
Apply molybdenum disulfide grease to the areas shown in
illustration.
201RW 010-X
4. W hen replacing the release bearing (3), replace both the
wedge collar (2) and wire ring (1) at the same time.
201RS013
Wedge Collar
1. Visually check the surfaces of the wedge collar makingcontact with the release bearing for excessive wear and
damage.
2. Replace any exhibiting excessive wear or damage.

RTW 77CSH000701
Shift Fork
1. Visually check the surfaces of the shift fork making contact with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from shift fork with an oil stone.
3. Replace any exhibiting excessive wear or damage.
4.
Apply molybdenum disulfide grease to the pin hole inner
circumferences and thrust surfaces.



RTW 57CSH000401

Release Bearing (MSG, MUA)
1. Visually inspect the surfaces of the release bearing making contact with the shift fork for excessive wear and damage.
Replace any exhibiting excessive wear or damage.
2. Apply multi-purpose type grease (NLGI No.2 or No.3) to contact surface between the release bearing and the shift
fork. (Do not apply grease to the sleeve inner face.)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7C-30 CLUTCH


RTW 57CSH000201

Shift Fork
1. Visually inspect the surfaces of the shift fork making contact
with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from the release bearing with an oil stone.
Replace any exhibiting excessive wear or damage.
3. Apply multi-purpose type grease (NLGI No.2 or No.3) to
area.





RTW 57CSH000501




DRIVEN PLATE ASSEMBLY
1. Visually inspect the torsion spring 1 for looseness,
breakage, and weakening.
If any of these conditions are discovered, the driven plate assembly must be replaced.



2. Visually inspect the facing surfaces
2 for cracking and
excessive scorching.
Visually inspect the facing surfaces for the presence of oil or grease.
If any of these conditions are discovered, the facing must be cleaned or replaced.



3. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed with an oil stone.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

CLUTCH 7C-31


Driven Plate Warpage
1. Insert the clutch pilot aligner into the driven plate splinedhub.
The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner : 5-8525-3001-0
2. Set a dial indicator to the driven plate outside circumference.
3. Slowly turn the driven plate.
Read the dial indicator as you turn the driven plate.
If the measured value exceeds the specified limit, the driven plate assembly and/or the facing must be replaced.
Driven Plate W arpage mm(in)
Standard Limit
0.7 (0.028)1.0 (0.039)




Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft spline.
3. Set a surface gauge to the driven plate outside circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven plate.
If the measured value exceeds the specified limit, the driven plate assembly must be replaced.
Driven Plate Splined Hub Spline W ear mm(in)
Standard Limit
0.5 (0.020)1.0 (0.039)



Rivet Head Depression
Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression
1 from the facing surface
2.
Be sure to measure the rivet head depression on both sides of
the driven plate.
If the measured value is less than the specified limit, the facing
must be replaced.
Rivet Head Depression mm(in)
Standard
Fly wheel side P/Plate side Limit
4J
series 1.35-1.95
(0.053-0.077) 1.65-2.25
(0.065-0.089) 0.2
(0.008)
C24SE 1.65-2.25
(0.065-0.089) 1.65-2.25
(0.065-0.089) 0.2
(0.008)
4JJ1
(High Output)
1.40-2.00
(0.055-0.079) 1.70-2.30
(0.067-0.091) 0.2
(0.008)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

7C-32 CLUTCH
CLUTCH CONTROL
REMOVAL AND INSTALLATION




RTW 77CLF000601

Removal Steps
1. Pin
2. Jaw joint pin
3. Pedal assembly
4. Oil line
5. Master cylinder assembly
6. Oil line
7. Slave cylinder assembly
8. Damper cylinder assembly

Installation Steps
8. Damper cylinder assembly
7. Slave cylinder assembly
6. Oil line
5. Master cylinder assembly
4. Oil line
3. Pedal assembly
2. Jaw joint pin
1. Pin



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007