oil ISUZU TFS SERIES 1997 Repair Manual

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.

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.

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-46 CLUTCH
3. CLUTCH SHUDDER
Checkpoint Trouble Cause Countermeasure
Grease or oil adhering to the
facing
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Replace the pressure plate
assembly
Defective transmission front
cover oil seal
Pressure plate unevenly wornPressure plate
Clean the related parts and/or
replace the facing
Tighten the connections
Repair or replace the
applicable parts
Too much grease
Poorly connected components
causing looseness and
abrasion
OK
NG NG NG NG
OK
Power train
Clean and grease the spline
contact surface
Insufficient grease on the
spline contact surface of the
splined hub
Driven plate
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Corrosion or step wear on the
top gear shaft spline
Defective crankshaft rear oil
seal
OKNG NG NG
OK
Continued on the next page