ISUZU TROOPER 1995 Workshop Manual

Pilot aligner: J-24547
• Mark the flywheel, clutch cover and pressure
plate lug for alignment when installing.
4. Release bearing
• Remove the release bearing from the
transmission case (Fig. 7C-9).
5. Shift fork
• Remove the snap pin.
• Remove the shift fork pin and shift fork from the
fulcrum bridge (Fig. 7C-10).
!
Fig. 7C-9
Fig. 7C-10
6. Fulcrum bridge
• Remove the fulcrum bridge bolts.
•
Remove the fulcrum bridge from the
transmission case (Fig. 7C-11).
7. Flywheel assembly and crankshaft bearing
• Do not remove except for replacement.
~~~· Use the remover to remove the crankshaft
bearing (Fig. 7C-12).
Remover; J-5822
Sliding hammer; J-23907
Fig. 7C-11
Fig. 7C-12
[L!j INSPECTION AND REPAIR
CLUTCH 7C-7
Make necessary correction or parts replacement if
wear, damage, or any other
abnormal condition are
found through inspection.
Pressure plate assembly (Fig. 7C-13)
• Visually check the pressure plate friction
surface
for excessive wear and heat cracks.
If excessive wear or deep heat cracks are
present, the pressure
plate must be replaced.
e ·---------
Fig. 7C-13

7C-8 CLUTCH
I~U Pressure plate warpage (fig. 7C-14)
• Use a straight edge and a feeler gauge to
measure the pressure plate friction surface
flatness in
four directions.
If any of the measured values exceeds the
specified limit, the pressure plate
must be
replaced.
Pressure plate warpage
Limit
0.3 (0.012)
Fig. 7C-14
Clutch cover (fig. 7C-15)
mm (in)
• Visually check the entire clutch cover for
excessive wear, cracking, and other damage.
The clutch cover
must be replaced if any of
these conditions are present.
Fig. 7C-15
jQI Clutch set force (Fig. 7C-16)
1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure
plate.
A metal sheet
with @ 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® 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 (lb)
Standard Limit
7:208 (1621) 6669 (1499)
Fig. 7C-16
1•1 Diaphragm spring finger height (fig. 7C-17)
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.
a. Use a bench press to press down on the
asst~mbly from the top.
b. Tighten the fixing bolts.
IDNOTE:
Yf Pre-Load on diaphragm spring finger must be 49-
98N
(11-~~2 lb) in direction of release, when clutch
cover
assembly is bolted to the flywheel.
3. Measure the spring height from base to spring
tip@.
If the measured value exceeds the specified
limit, the pressure plate assembly
must be
replaced.
Spring finger height
mm (in)
Standard
49.9 -51.9 (1.965 -
2.043))
•

Fig. 7C-17
mm (0.315 in)
Driven plate assembly (Fig. 7C-18)
Release
t
• Visually check the torsion spring for looseness,
breakage, and weakening.
If any of these conditions are discovered, the
driven
plate assembly must be replaced.
• Visually check the facing surfaces 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.
• 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.
Fig. 7C-18
CLUTCH 7C-9
Driven plate warpage (Fig. 7C-19)
l'fil1. Insert the clutch pilot aligner into the driven
1.!!!1 plate splined hub.
li5\l The clutch pilot aligner must be held perfectly
I.::2Y horizontal.
Clutch pilot
aligner; J-24547
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 must be
replaced.
Driven
plate warpage mm (in)
Standard Limit
0.7 (0.028) 1.0
(0.039)
Fig. 7C-19
Driven plate splined hub spline wear
(Fig.
7C-20)
E1 1. Clean the driven plate splined hub.
l...al 2. Install the driven plate to the transmission top
ffi1 gear shaft spline.
1.!!1 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-1 0 CLUTCH
Fig. 7C-20
I til!. I Rivet head depression (Fig. 7C-21}
• Use a depth gauge or a straight edge with steel
rule
to measure the rivet head depression CD
from the facing surface ®.
• 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 driven plate assembly must be
replaced.
Rivet head depression
Standard
1.6
(0.063)
CD ®
~··· ·$~,i ') ; :. : .: ::,:. . ~· ,• · . .' : ·.· :· .. , .
Fig. 7C-21
Release bearing (Fig. 7C-22}
mm (in)
Limit
0.2 (0.008)
• Visually
check the release bearing for
excessive play, noise and breakage.
If any of these conditions are discovered, the
release bearing must be replaced.
•
When replacing the release bearing, replace
both the wedge collar and wire ring at the same
time (Fig. 7C-22a). Fig.
7C-22
/ Wire
ring
ENG side
'· ~ T/M side
Fig. 7C-22a
Wedge collar (Fig. 7C-22b}
Pressure plate
assembly
Release bearing
• Visually check the surfaces of the wedge
collar making contact with the release
bearing for excessive wear and damage.
• Replace any exhibiting excessive wear or
damage.
Fig.
7C-22b
•

Shift fork (Fig. 7C-23)
• Visually check the surfaces of the shift fork
making contact
with the release bearing for
excessive wear and damage.
• Remove any minor stepping or ah,rasion from
shift fork with an oil stone.
Replace any exhibiting
· ex«?~ssive wear or
damage.
Fig.
7C-23
1••1 INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points:
7. Flywheel assembly and crankshaft bearing
§I• Clean and lubricate with grease.
1®..1• Use the installer to install the crankshaft
bearing (Fig. 7C-24).
Installer: J-26516-A
Driver handle: J-8092
Fig.
7C-24
CLUTCH 7C-11
• Bolts: flywheel fixing (Fig. 7C-25)
• Install new bolts in the order illustrated and
tighten them to the specified torque.
1~1 Torque N·m (lb·ft) I 54 (40)
6.
NOTE:
• Do not reuse the bolt.
•
Do not apply oil or thread lock to the bolt.
Fig. 7C-25
Fulcrum bridge (Fig. 7C-26)
• Install the fulcrum bridge to the transmission
case.
• Tighten three fulcrum bridge bolts to the
specified torque.
I~I __ T_o_rq~u_e __ N_·_m~(_lb_·ft_l~ _____ 3_8_(_28_) ____ _
5. Shift fork (Fig. 7C-27)
• Apply molybednum disulfide contained type
grease
to the pin hole inner circumferences
and thrust surfaces.
• Attach the shift fork to the fulcrum bridge and
insert the pin
from below of the fulcrum bridge.
• Install the washer and snap pin.
Fig.
7C-26

7C-12 CLUTCH
Apply grease
Fig. 7C-27
4. Release bearing
r;:J • Apply molybdenum disulfide contained type
D grease to the areas shown in Fig. 7C-28.
• Install the release bearing to the in the proper
direction (Fig.
7C-29).
U7 NOTE:
VI Ensure release bearing is properly positioned
during
installation, as shown in Fig. 78-29.
Fig. 7C-28
Fig. 7C-29
3. Driven plate assembly
liQ\1 • Use the pilot aligner to install the driven plate
~ assembly (Fig. 7C-30).
Pilot aligner; J-24547
Fig. 7C-30
2. Pressure plate assembly
• Tighten the bolts holding the pressure plate
assembly in the order shown in
Fig. 7C-31.
1~1 Torque N·m (lb·ft) I 18 (13)
• Remove the aligner.
UJNOTE:
VI Do not strike the aligner with a hammer to remove
it.
1. Transmission assembly
Fig. 7C-31
•

CLUTCH CONTROL
5
Removal steps
1. Pin & 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 13
Fig. 7C-32

7C 14 CLUTCH
1••1 REMOVAL
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
ll.•l INSPECTION AND REPAIR
Make necessary adjustments, repairs, and part
replacement
if wear, damage or other problems are
discovered during inspection.
1••1 INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points:
1. Clutch pedal adjustment
(1) With clutch switch (Fig. 7C-33)
• Disconnect clutch switch connector.
• Loosen lock nut, then turn switch out until
there is a gap between the switch plunger
and
clutch pedal.
(2) Loosen clutch master cylinder push rod lock
nut. Turn push rod by hand to set clutch
pedal height (H2) to
within specification (Fig.
7C-34).
Clutch
pedal height (H2 ) mm (in)
218.5
-228.5 (8.602 -8.996)
Clutch switch
With Clutch switch
Fig. 7C-33
Floor panel
Fig. 7C-34
(3) Tighten push rod lock nut.
(4) With clutch switch
Clutch pedal height
•Turn the clutch switch until the switch bolt
justtouches the clutch pedal arm (Fig. 7C­
:~5).
•Adjust clutch switch by backing it out half
a
turn, and measure the clearance (o)
betweeen the clutch pedal arm and the
c:lutch switch (Fig. 7C-36).
•Lock the lock nut.
•Connect clutch switch connector.
Clutch switch and clutch
pedal
clearance
(o) mm (in)
0.5 -1.5 (0.020 -0.059)
(5) After adjusting the clutch pedal height, push
the clutch pedal
by hand rightly to check the
clutch pedal free play (H1) to within
specification (Fig. 7C-34).
Pedal free play (H1) mm (in)
5 -
15 (0.20 -0.59)
Fig. 7C-35
•

Fig. 7C-36
(6) Clutch pedal engagement height inspection
(Fig.
7C-37)
block the wheels.
® Start the engine, fully step on the clutch
pedal,
and move the shift lever to 1st
position.
@ With the engine idling, release the
clutch pedal slowly and measure its
stroke -just prior
to its clutching
position.
Clutch pedal engagement height (H3) mm (in)
MIN. 30 (1.18)
If the
measured value exceeds the specified
limit, check the following points. Repair if
necessary.
• Hydraulic circuit for fluid leakage or air in
circuit.
• Clutch disc warped.
• Diaphragm spring weakened or tip of
fingers worn.
• Driven plate sticking on sprines.
• Release bearing worn or damaged.
• Master cylinder and slave cylinder worn.
Floor panel
Fig. 7C-37
CLUTCH 7C-15
2. Torque N·m (lb·ft)
Master cylinder to dash panel 16 (12)
Clutch pedal to dash panel 21 (15)
Master cylinder push rod to yoke 17 (12)
Clutch pipe to master cylinder 20 (14)
Clutch pipe
to damper cylinder 12
(104 lb·in)
Clutch
pipe to flex, hose 20 (14)
Slave cylinder to case 43 (32)
Slave
cylinder bleeder screw 8 (691b·in)
Clutch
pipe to slave cylinder 20 (14)
Damper cylinder bleeder union nut 49 (36)
Damper cylinder bleeder pipe 15 (11)
Damper cylinder
bleeder screw 8 (69 lb·in)
3. Bleeding
(1) Check
the level of clutch fluid in the reservoir
and
replenish if necessary (Fig. 7C-38).
Fig. 7C-38
Bleeding the damper cylinder (Fig. 7C-39)
Damper cylinder
Fig. 7C-39

7C-16 CLUTCH
(2) Remove the rubber cap from the bleeder
screw and wipe clean the bleeder screw.
Connect a vinyl tube to the bleeder screw
and insertthe other end
of the vinyl tube into
a transparent container.
(3) Pump the clutch pedal repeatedly and hold it
depressed (Fig. 7C-40).
Fig. 7C-40
(4) Loosen the bleeder screw to release clutch
fluid with air bubbles into the container, then
tighten the bleeder screw immediately.
(5) Release the clutch pedal carefully. Repeat
the above operation until air bubbles
disappear from the clutch fluid being
pumped out into the container. During the
bleeding operation, keep the
clutch fluid
reservoir filled to the specified level.
Reinstall the rubber cap.
Bleeding
the slave cylinder (Fig. 7C·41)
(6) Repeat steps (2) through (5) for bleeding the
slave cylinder.
Vinyl tube
Fig. 7C-41
•