engine ISUZU TFS SERIES 1997 Owner's Manual

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.

CLUTCH 7C-7
PRESSURE PLATE ASSEMBLY
HEC Engine Series4J Engine Series
6VD1 Engine Series
The pressure plate assembly consists of the clutch cover, the pressure plate with diaphragm spring.
Operating the clutch pedal causes the pressure plate to move in an axial direction to engage and disengage the
clutch.
DRIVEN PLATE ASSEMBLY
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.

CLUTCH 7C-9
SPECIAL PARTS FIXING NUTS AND BOLTS
Nm (kgfm/lbft)
HEC Engine Series LHD Model
19.63.9 (2.00.4/14.52.9)
11.8
2.9 (1.20.3/8.82.2) 15.7
4.9 (1.60.5/11.63.6)15.7
2.9 (1.60.3/11.62.2) 17.6
4.9 (1.80.5/13.03.6)

7C-10 CLUTCH
Nm (kgfm/lbft)
HEC Engine Series RHD Model, 4J Engine Series
19.63.9
(2.0
0.4/14.52.9)7.85
0.95
(0.8
0.1/5.80.7) 11.8
2.9
(1.2
0.3/8.82.2) 15.7
2.9
(1.6
0.3/11.62.2)

CLUTCH 7C-13
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
CLUTCH PEDAL HEIGHT
Inspection
Measure to verify that the distance from the upper surface of
the pedal pad to the firewall is within the standard value.
Clutch Pedal Height(H) mm(in)
RHD LHD
HEC ENGINE216-226
(8.50-8.89)178-188
(7.01-7.40)
4JG2T ENGINE185.5-195.5
(7.30-7.70)
OTHER ENGINE203-213
(7.99-8.39)178-188
(7.01-7.40)
Adjustment
1. Loosen clutch master cylinder push rod lock nut
2.
Turn push rod

1 by hand to set clutch pedal height (H) to
within specification.
2. After the adjustment, tighten lock nut

2.
3. Turn the clutch switch

3 or stopper bolt
3 until the switch
bolt

3 or stopper bolt
3 just touches the clutch pedal arm.
Adjust clutch switch

3 or stopper bolt
3 by backing it out
half a turn, and measure the clearance (L) between the
clutch pedal arm and the clutch switch bolt end

3 or
stopper bolt

3.
Lock the lock nut

4.
Connect clutch switch connector.
Clutch switch and clutch pedal
Clearance mm(in)
(L) 0.5-1.5 (0.020-0.059)
CLUTCH PEDAL PLAY
Inspection
Depress the clutch pedal lightly by hand, and measure to
determine if the free play is within the standard value.
Pedal Free Play mm(in)
H1 5.0-15.0 (0.2-0.6)

CLUTCH 7C-15
CLUTCH
REMOVAL AND INSTALLATION
HEC Engine Series
4J Engine Series
6VD1
Removal Steps
1. Transmission assembly
2. Pressure Plate assembly
3. Driven plate assembly
4. Release bearing
5. Shift fork
6. Flywheel assembly and cran bearing
(HEC Engine Series)7. Fulcrum bridge (6VD1)Installation Steps
To install, follow the removal steps in the
reverse order.

7C-16 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 (HEC Engine Series)
3. Driven Plate Assembly (HEC Engine Series)
(1) Use the clutch pilot aligner

1 to prevent the driven plate
assembly

2 from falling free.
Clutch Pilot Aligner : 5-8840-2634-0
(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.
3. Driven Plate Assembly (Except HEC Engine Series)
(1) Use the pilot aligner to prevent the driven plate assembly
from falling free.
Pilot aligner: 5-8525-3001-0 (J-24547)
(2) Mark the flywheel, clutch cover and pressure plate lug for
alignment when installing.
6VD14. Release Bearing (6VD1)
Remove the release bearing from the transmission case.

CLUTCH 7C-17
6VD15. Shift Fork (6VD1)
(1) Remove the snap pin.
(2) Remove the shift fork pin and shift fork from the fulcrum
bridge.
6VD17. Fulcrum Bridge (6VD1)
(1) Remove the fulcrum bridge bolts.
(2) Remove the fulcrum bridge from the transmission case.
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.
3. Driven plate Assembly (HEC Engine Series)
2. Clutch Pressure Plate Assembly (HEC Engine Series)
(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 : 5-8840-2634-0
(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 (kgfm/lbft)
17.6
4.9 (1.8 0.5/13.0 3.6)

CLUTCH 7C-19
6VD1(2) Install the release bearing in the proper direction.
3. Driven Plate Assembly (Except HEC Engine Series)
Use the pilot aligner to install the driven plate assembly.
Pilot aligner: 5-8525-3001-0 (J-24547)
6VD12. Pressure Plate Assembly (6VD1)
(1) Tighten the bolts holding the pressure plate assembly in the
order shown in illustration.
Pressure Plate Bolt Torque N
m (kgfm/lbft)
20.6
2.9 (2.10.3/15.22.2)
(2) Remove the aligner.
NOTE:
Do not strike the aligner with a hammer to remove it.
1. Transmission Assembly

CLUTCH 7C-25
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.
Driven Plate Warpage
1. Insert the clutch pilot aligner into the driven plate splined
hub.
The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner : 5-8840-2634-0 (HEC Engine Series)
5-8525-3001-0 (J-24547) (Except HEC Engine Series)
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 Warpage 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 Wear mm(in)
Standard Limit
0.5 (0.020) 1.0 (0.039)