c24se ISUZU TF SERIES 2004 User Guide

7C-14 CLUTCH
C24SE
RTW37CSF0003

The driven plate assembly consists of the plate and the facing.
The plate consists of the clutch center, the cushioning plate and the torsion springs.
The facing is riveted to both sides of the cushioning plate.
The cushioning plate provides a longer service life by minimizing wear and vibration at the clutch contact surfaces.

7C-18 CLUTCH
C24SE
N
m (kgf
m/lb ft)
RTW37CLF000301

7C-22 CLUTCH


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


2. Clutch 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 : 5-85253-001-0





(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.

201RS017


220RW088-X

4. Release Bearing (6VE1)
5. Shift Fork (6VE1)

(1) Remove the release bearing (1) from the transmission
case.
(2) Remove the shift fork snap pin (2).
(3) Remove the shift fork pin and shift fork (3) from the fulcrum
bridge.
6VE1 4JH1-TC, C24SE

CLUTCH 7C-25


(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)

201RS017




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


4JH1-TC, C24SE
6VE1

CLUTCH 7C-27
201R300011


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
6VE1 8.2 (0.323) 12 (0.472)
4JA1T(L) 7.8 (0.307) 20 (0.787)
4JA1TC/
4JH1TC 7.8 (0.307) 18 (0.71)
C24SE 8.0 (0.315) 7.9 (0.311)
4. Note the pressure plate gauge reading.
Driven Plate Clamping Load N (kg/Ib)

Standard
6VE1 7200 (734/1618)
4JA1T(L) 5070 (517/1140)
4JA1TC/4JH1TC 6300 (642/1415)
C24SE 5500 (561/1237)

RTW37CSH000101
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.

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
6VE1 8.2 (0.323) 12 (0.472)
4JA1T(L) 7.8 (0.307) 20 (0.787)
4JA1TC/
4JH1TC 7.8 (0.307) 18 (0.71)
C24SE 8.0 (0.315) 7.9 (0.311)
Finger Height

6VE1 49.9-51.9 (1.96-2.04)
4JA1T(L) 31-33 (1.22-1.30)
4JA1TC/
4JH1TC 39-41 (1.54-1.61)
C24SE 39-41 (1.54-1.61)

CLUTCH 7C-29
201RS011
Release Bearing (6VE1)
1. Visually check the release bearing for excessive play, noise
and breakage.
2. If any of these conditions are discovered, the release
bearing must be replaced.

201RW010-X

3. When 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 making
contact with the release bearing for excessive wear and
damage.
2. Replace any exhibiting excessive wear or damage.
201RS014
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.


Release Bearing (4J, C24SE)
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.)

CLUTCH 7C-31



Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaf
t
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 Wear 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 1.35-1.95
(0.053-0.077) 1.65-2.25
(0.065-0.089) 0.2
(0.008)
6VE1
C24SE 1.65-2.25
(0.065-0.089) 1.65-2.25
(0.065-0.089) 0.2
(0.008)

CLUTCH 7C-35
SLAVE CYLINDER (4J, C24SE)
DISASSEMBLY



Disassembly Steps


1. Boot
2. Push rod
3. Piston and piston cup


4. Spring
5. Cylinder body




Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.

8A-2 ELECTRICAL-BODY AND CHASSIS
PAGE
Fuse and Slow Blow Fuse Location (Relay and Fuse Box) .................................... 8A- 31
Fuse Location ............................................................................................................. 8A- 33
Diode Location ........................................................................................................... 8A- 34
Fuse Block Circuit ...................................................................................................... 8A- 35
Fuse Block Circuit (C24SE) ....................................................................................... 8A- 35
Fuse Block Circuit (6VE1) ......................................................................................... 8A- 37
Fuse Block Circuit (4JA1-TC/4JH1-TC) - RHD ......................................................... 8A- 39
Fuse Block Circuit (4JA1-TC/4JH1-TC) – LHD ......................................................... 8A- 41
Fuse Block Circuit (4JH1-L) ...................................................................................... 8A- 43
Grounding Point ............................................................................................................. 8A- 45
Ground Point .............................................................................................................. 8A- 45
Ground Point Location .............................................................................................. 8A- 61
Main Cable harness Routing .......................................................................................... 8A- 63
C24SE / 6VE1 / 4JA1-L / 4JH1-TC .............................................................................. 8A- 63
Instrument Harness .................................................................................................... 8A- 71
System Repair .................................................................................................................8A- 73
Start and Charging ..................................................................................................... 8A- 73
Engine Control Module (ECM) ................................................................................... 8A- 89
Exhaust Gas Recalculation (EGR): 4JA1-L Only ...................................................... 8A- 109
Lighting ....................................................................................................................... 8A- 114
Front Fog Light ........................................................................................................... 8A- 136
Rear Fog Light ............................................................................................................ 8A- 144
Head Light Leveling ................................................................................................... 8A- 149
Illumination ................................................................................................................. 8A- 154
Hazard Warning Flasher, Turn Signal Light, Back Up Light,
Horn and Stop Light ................................................................................................. 8A- 161
Dome Light, Spot Light and Warning Buzzer .......................................................... 8A- 181
Windshield Wiper and Washer .................................................................................. 8A- 196
Transmission Control Module (TCM) ....................................................................... 8A- 214
Meter, Warning Light and Indicator Light ................................................................ 8A- 223
Heater and Air Conditioning ...................................................................................... 8A- 281
Power Door Lock ....................................................................................................... 8A- 293