1995 ISUZU TROOPER Workshop Manual

CLUTCH 7C-3
MASTER CYLINDER
Fig. 7C-2
DAMPER CYLINDER
Fig. 7C-3
In order to reduce the occurrence of noises at the
clutch hydraulic system, the damper cylinder is used in the
clutch
hydraulic line between the master cylinder
and slave cylinder.
SLAVE CYLINDER
Fig. 7C-4

7C-4 CLUTCH
PRESSURE PLATE ASSEMBL V
Fig. 7C-5
DRIVEN PLATE ASSEMBL V
Fig. 7C-6
•

CLUTCH 7C-5
DIAGNOSIS
Problem Possible cause Correction
Dragging • Fluid leakage.
• Repair
• Air in hydraulic line.
• Bleed
•
Master cylinder and slave cylinder seals • Replace seals.
worn.
• Driven plate warped. • Replace driven plate.
•
Diaphragm spring weakened or tip of • Replace pressure plate.
fingers worn.
• Driven plate sticking on splines. • Lubricate with grease or replace.
• Clutch spline
worn. • Repair
• Release bearing worn or damaged. • Replace release bearing.
Slipping
• Driven plate facing worn or oil soaked. • Replace driven plate and check for
leaks.
•
Diaphragm spring weakened. • Replace pressure plate.
•
Pressure plate or flywheel warped. • Correct or replace.
•
Master cylinder and slave cylinder seals
• Replace seals.
worn.
Chattering
• Engine mounts loose or damaged. • Tighten or replace.
•
Driven plate facing warped. • Replace driven plate.
•
Surface of facing hardened. • Replace driven plate
•
Driven plate facing oil soaked. • Replace driven plate and check for
leaks.
•
Damper springs weakened or broken. • Replace.
•
Pressure plate or flywheel warped. • Correct or replace.
Noisy • Replace bearing binding. • Correct, or replace if damaged, and
lubricate.
• Replace
bearing worn or damaged. • Replace release bearing.
• Release bearing poorly lubricated.
• Lubricate.
• Pilot bearing worn. • Replace pilot bearing.
• Damper springs weakened or broken. • Replace driven plate.
•
Rivets of driven plate exposed. • Replace driven plate.
Pedal
is hard • Hydraulic line blocked.
• Clean out or replace.
to push • Master or slave cylinders binding. • Repair or replace as needed.

7C-6 CLUTCH
ON-VEHICLE SERVICE
CLUTCH ASSEMBL V
6
Removal steps
1••1 REMOVAL
1. Transmission assembly
2. Pressure plate assembly
3. Driven plate assembly 4. Release bearing 5. Shift fork
6. Fulcrum bridge
7. Flywheel assembly and
crankshaft bearing
1. Transmission assembly
3
Fig. 7C-7
Refer to "MANUAL TRANSMISSION" of Section
78
for "REMOVAL AND INSTALLATION" pro­
cedure.
2. Pressure plate assembly
3. Driven plate assembly
li0\1 • Use the pilot aligner to prevent the driven plate
lSi~ assembly from falling free (Fig. 7C-8).
2
Installation steps
To install,
follow the removal steps in the reverse order.
Drivtm plate assembly
Pressure plate assembly'
Pilot aligner
Fig. 7C-8
•

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))
•