ISUZU TFS SERIES 1997 Workshop Manual

CLUTCH 7C-21
Clutch Set Force (Except 6VD1)
1. Position the pressure plate assembly
1 as shown in the
illustration.
2. Place the new driven plate

2 over the pressure plate
assembly.
Driven Plate Thickness (Reference) mm(in)
Standard
Free Compressed
HEC (MSG) 8.4 (0.330) 8.0 (0.315)
HEC (MUA) 8.6 (0.338) 8.0 (0.315)
4JG2T 8.2 (0.323) 8.0 (0.315)
4JA1 8.0 (0.315) 7.8 (0.307)
4JB1T 8.0 (0.315) 7.8 (0.307)
3. Place a metal sheet
3 between the press and the driving
plate.
4. Compress the metal sheet and the driven plate until the
driven plate is flush with the drive plate assembly

A.
5. Note the pressure gauge reading.
Driven Plate Slamping Force N (kg/Ib)
Standard
HEC (MSG), 4JA1 4,903 (500/1,103)
HEC (MUA), 4JB1T 5,492 (560/1,235)
4JG2T 6,276 (640/1,411)
Clutch Set Force (6VD1)
1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate.
A metal sheet with
A thickness of 8.0 mm (0.315 in) may
be used in place of the driven plate.
3. Compress the pressure plate assembly until the distance
B
becomes 12 mm (0.472 in).
4. Note the pressure gauge reading.
If the measured value is less than the specified limit, the
pressure plate assembly must be replaced.
Clutch Set Force N (kg/Ib)
Standard Limit
6VD1 7,208 (735/1,621) 6,669 (680/1,499)

7C-22 CLUTCH
Diaphragm Spring Finger Height
(Except 6VD1)
1. Place the appropriate spacer beneath the pressure plate.
Refer to the table below.
Spacer Thickness mm(in)
HEC, 4JG2T 8.0 (0.315)
4JA1, 4JB1T 7.8 (0.307)
2. Fully compress the pressure plate and the diaphragm
spring.
There are two ways to do this.
1) Use a bench press to press down the assembly from the
top.
2) Tighten the fixing bolts.
3. Measure the spring finger height

A from the base to the
spring tip.
Spring Finger Height mm(in)
HEC MSG 37-39
HEC MUA 39.9-41.9
4JA1 30.5-32.5 (1.20-1.28)
4JB1T 35.0-37.0 (1.38-1.46)
4JG2T 39.0-41.0 (1.53-1.61)
6VD1Diaphragm Spring Finger Height (6VD1)
1. Place a new driven plate or a 8.0 mm (0.315 in) spacer
beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm spring.
There are two ways to do this.
1) Use a bench press to press down on the assembly from
the top.
2) Tighten the fixing bolts.
NOTE: (6VD1)
Pre-load on diaphragm spring finger must be 49 - 98N (5.0
- 10.0 kg / 11 - 22 lb) in direction of release, when clutch
cover assembly is bolted to the flywheel.
3. Measure the spring height from base to spring tip
A.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Spring Finger Height mm(in)
Standard
6VD1 49.9-51.9 (1.965-2.043)

CLUTCH 7C-23
Release Bearing Replacement
Removal (Except 6VD1)
Use the bearing puller and the adapter to remove the release
bearing.
Bearing Puller : 5-8840-0013-0 (J-22888)
Adapter : 5-8840-0124-0 (J-2241-11)
Release Bearing Installation (Except 6VD1)
1. Set the release bearing to the shift block bearing fitting
surfaces.
The release bearing must be perfectly horizontal.
2. Use a bench press to fit the release bearing to the shift
block.
Install the parts as illustrated after applying wheel bearing
grease or multi-purpose type grease (NLGI No.2 or No.3).
6VD1Release Bearing (6VD1)
1. Visually check the release bearing for excessive play, noise
and breakage.
If any of these conditions are discovered, the release
bearing must be replaced.
6VD1NOTE:
When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.

7C-24 CLUTCH
Wedge Collar (6VD1)
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 damage.
Shift Fork (Except 6VD1)
1. Visually inspect the surfaces of the shift fork making contact
with the shift block for excessive wear and damage.
2. Remove any minor stepping or abrasion from the shift block
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.
6VD1Shift Fork (6VD1)
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.
Replace any exhibiting excessive wear of damage.
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.

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)

7C-26 CLUTCH
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
HEC 1.652.25
(0.065-0.089)
4JA1 1.351.95
(0.053-0.077)1.652.25
(0.065-0.089)0.2
(0.008)
4JB1T, 4JG2T 1.31.9
(0.051-0.075)
6VD1 1.6 (0.063)
Limit

CLUTCH 7C-27
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Except 6VD1 Engine
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
To install, follow the removal steps in the
reverse order.

7C-28 CLUTCH
6VD1 RHD Model
Removal Steps
1. Pin and jaw joint pin
2. Pedal assembly and switch
3. Oil line pipe
4. Slave cylinder assembly and heat
protector
5. Master cylinder assembly
6. Damper cylinder assembly
Installation Steps
To install, follow the removal steps in the
reverse order.

CLUTCH 7C-29
6VD1 LHD Model
Removal Steps
1. Pin and jaw joint pin
2. Pedal assembly and switch
3. Oil line pipe4. Slave cylinder assembly
5. Master cylinder assmebly
6. Oil line hose
Installation Steps
To install, follow the removal steps in the
reverse order.

7C-30 CLUTCH
MASTER CYLINDER (Except 6VD1 Engine)
DISASSEMBLY
Repair Kit
Disassembly Steps
1. Oil tank band
2. Oil tank assembly
3. Joint
4. Lock nut
5. Dust cover6. Stopper ring
7. Stopper
8. Push rod
9. Piston assembly
10. Cylinder body
Important : Take care not to disassemble the push rod stopper for master cylinder which calk to the master cylinder
body due to the component parts do not disassemble.