ISUZU TFS SERIES 1997 Workshop Manual

CLUTCH 7C-31
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it if
necessary.
Cylinder Bore and piston Clearance
1. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. Calculate the clearance between the cylinder bore and the
piston diameter.
If the clearance exceeds the limit, the entire slave cylinder
assembly must be replaced.
Cylinder Bore and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.006)
Inner Parts
Replace the inner parts with new parts shown in the illustration.

7C-32 CLUTCH
REASSEMBLY
* Apply grease
(COSMO rubber grease)
Repair Kit
Reassembly Steps
1. Cylinder body
2. Piston and assembly
3. Push rod
4. Stopper
5. Stopper ring6. Dust cover
7. Lock nut
8. Joint
9. Oil tank assembly
10. Oil tank band
Important Operations
1. Cylinder Body
Immerse the cylinder body in clean brake fluid.

CLUTCH 7C-33
Master Cylinder (6VD1 LHD Model)
DISASSEMBLY AND REASSEMBLY
Disassembly Steps
1. Reservoir cap
2. Base cap
3. Seal
4. Clip
5. Reservoir
6. Gasket
7. Yoke
8. Nut
9. Rod stopper10. Push rod
11. Piston assembly
12. Plate
13. O-ring
14. Damper ring
15. Diaphragm
16. Seal ring
17. Cylinder body
Reassembly Steps
To reassemble, follow disassembly
steps in the reverse order.
Disassembly
1. Disassemble reservoir cap 1., base cap 2., seal
3., clip 4., and reservoir 5..
2. Disassembly gasket 6., yoke 7., and nut 8..
3. Disassemble rod stopper 9., push rod 10., and
piston assembly 11..4. Disassemble plate 12., o-ring 13., damper ring
14., diaphragm 15., and seal ring 16. from
cylinder body 17..

7C-34 CLUTCH
Inspection and Repair
Make the necessary adjustments, repair, and part
replacements if excessive wear or damage is
discovered during inspection.
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean
it if necessary.
Inner Parts
1. Visually inspect the disassembled parts for
excessive wear and damage.
Replace the inner parts with new parts shown in the
illustration.
2. Measure the clearance between master cylinder
wall and piston.
If the measured value exceeds the specified limit,
the master cylinder assembly must be replaced.
Standard: 0.07 mm (0.0028 in)
Limit: 0.15 mm (0.0059 in)
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
Cylinder Body
Immerse the cylinder body in clean brake fluid.
Piston Assembly
Before installing, apply a thin coat of rubber grease to
the piston. Install cup in groove in piston with lip turned
to front of cylinder. Use care to prevent damaging the
lip of the piston seat.

CLUTCH 7C-35
SLAVE CYLINDER (Except 6VD1 Engine)
DISASSEMBLY
Disassembly Steps
1. Boot
2. Push rod
3. Piston and piston cup4. Spring
5. Cylinder body
6. Solenoid switch
Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.

7C-36 CLUTCH
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it if
necessary.
Cylinder Bore and piston Clearance
1. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. Calculate the clearance between the cylinder bore and the
piston diameter.
If the clearance exceeds the limit, the entire slave cylinder
assembly must be replaced.
Cylinder Bore and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.006)
Piston and Piston Cup
Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts (Repair kit A) shown in
the illustration.

CLUTCH 7C-37
REASSEMBLY
* Apply grease
(COSMO rubber grease)
Reassembly Steps
1. Cylinder body
2. Spring
3. Piston and piston cup4. Push rod
5. Boot
6. Solenoid switch
Important Operations
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.
3. Piston and piston Cup
1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the
illustration.
3) Install the piston and piston cup to the cylinder body.

7C-38 CLUTCH
SLAVE CYLINDER (6VD1 Engine)
6VD1
Disassembly Steps
1. Boot
2. Push rod
3. Piston and piston cup
4. Spring
5. Cylinder body
Reassembly Steps
To reassemble, follow disassembly steps in
the reverse order.
DISASSEMBLY
1. Boot
2. Push Rod
3. Piston and Piston Cup
4. Spring
5. Cylinder Body
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
6VD1Cylinder body
1) Clean the cylinder body.
2) Check the fluid return port for restrictions and clean it if
necessary.

CLUTCH 7C-39
6VD1Piston and piston cup
Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts shown in the illustration.
Measure the clearance between slave cylinder wall and piston
If the measured value exceeds the specified limit, the slave
cylinder assembly must be replaced.
Slave Cylinder Wall and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.0059)
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse
order, noting the following points:
6VD11. Piston Assembly
1) Before installing the parts, apply a thin coat of rubber
grease.
2) Install cup in groove in piston with the lip turned to the front
of cylinder. Use care so as not to scratch the cylinder.

7C-40 CLUTCH
HYDRAULEC DAMPER CYLINDER (Except 6VD1 Engine)
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Visually check for oil leakage and other damage.
If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.