clutch ISUZU TFS SERIES 1997 Repair Manual

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.

CLUTCH 7C-41
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage

7C-42 CLUTCH
1. CLUTCH SLIPPAGE
Checkpoint Trouble Cause Countermeasure
Adjust the push rod playNo push rod play in the master
cylinder NG
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Clean the related parts and/or
replace the facing
Repair or replace the
transmission front cover
Adjust the push rod play
Defective transmission front
cover oil seal
Continued on the next page
Grease or oil adhering to the
facingToo much grease
Transmission front cover
unevenly worn
No push rod play in the slave
cylinder
Clean and grease the shift
blockShift blockInsufficient grease on the front
cover contact surfaces
NG NG NG NG NG
OK
OK
Clutch pedal free play
OK

CLUTCH 7C-43
Checkpoint Trouble Cause Countermeasure
Replace the release bearingRelease bearing broken
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Defective crankshaft rear oil
seal
NG NG
OK OKGrease or oil adhering to the
facing
Clutch diaphragm springReplace the clutch pressure
plate assemblyW eak or broken clutch
diaphragm spring
Replace the driven plate
assemblyWorn facing
NG NG
OKFacing Continued from the previous page

7C-44 CLUTCH
2. CLUTCH DOES NOT RELEASE PROPERLY
Checkpoint Trouble Cause Countermeasure
Driven plateReplace the driven plate
Adjust the push rod play
Driven plate warped or
unevenly worn
Too much push rod play in the
slave cylinder
Hydraulic circuitBleed the hydraulic circuit
Adjust the push rod play
Air in the hydraulic circuit
Too much push rod play in the
master cylinder
OK
NG NG NG NG
OKClutch pedal free play
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Corrosion or step wear on the
top gear shaft spline
Pressure plateReplace the pressure plate
assembly
Clean and grease the splined
contact surface
Pressure plate unevenly worn
Insufficient grease on the
spline contact surface of the
splined hub
OKNG NG NG
OK
Continued on the next page

CLUTCH 7C-45
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