wheel ISUZU TF SERIES 2004 Workshop Manual

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-21
CLUTCH
REMOVAL AND INSTALLATION



RTW37CLF000201-X

Removal Steps
1. Transmission assembly


2. Pressure Plate assembly


3. Driven plate assembly
4. Release bearing
5. Shift fork


6. Flywheel assembly and crank bearing

Installation Steps
To install, follow the removal steps in the
reverse order.

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-23
015RW053
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Remove flywheel assembly and crankshaft bearing. Do no
t
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 crankshaf
t
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.

015RW054
6. Flywheel Assembly and Crank Bearing (6VE1)
(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)

6VE1 54 (5.5/40)
NOTE: Do not reuse the bolt and do not apply oil or thread lock
to the bolt.

7C-24 CLUTCH
201RW019
5. Shift Fork (6VE1)
4. Release Bearing (6VE1)
(1)
Apply molybdenum disulfide type grease to the pin hole
inner circumferences and thrust surfaces.
(2)
Attach the shift fork to the front cover and insert the pin
from below of the front cover.
(3) Install the washer and snap pin.
201RW012
(4) Apply molybdenum disulfide type grease to the areas
shown in illustration.
201RW020

(5) Install the release bearing in the proper direction.
NOTE: Ensure release bearing is properly positioned during
installation, as shown in illustration.




3. Driven plate Assembly
2. Clutch 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

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.

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)

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

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