1997 ISUZU TFS SERIES wheel

CLUTCH 7C-15
CLUTCH
REMOVAL AND INSTALLATION
HEC Engine Series
4J Engine Series
6VD1
Removal Steps
1. Transmission assembly
2. Pressure Plate assembly
3. Driven plate assembly
4. Release bearing
5. Shift fork
6. Flywheel assembly and cran bearing
(HEC Engine Series)7. Fulcrum bridge (6VD1)Installation Steps
To install, follow the removal steps in the
reverse order.

7C-16 CLUTCH
Important Operations - Removal
1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of section 7B and 7B1
for “REMOVAL AND INSTALLATION” procedure.
2. Clutch Pressure Plate Assembly (HEC Engine Series)
3. Driven Plate Assembly (HEC Engine Series)
(1) Use the clutch pilot aligner

1 to prevent the driven plate
assembly

2 from falling free.
Clutch Pilot Aligner : 5-8840-2634-0
(2) Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3) Remove the pressure plate assembly

3 from the flywheel.
(4) Remove the driven plate from the flywheel.
3. Driven Plate Assembly (Except HEC Engine Series)
(1) Use the pilot aligner to prevent the driven plate assembly
from falling free.
Pilot aligner: 5-8525-3001-0 (J-24547)
(2) Mark the flywheel, clutch cover and pressure plate lug for
alignment when installing.
6VD14. Release Bearing (6VD1)
Remove the release bearing from the transmission case.

CLUTCH 7C-17
6VD15. Shift Fork (6VD1)
(1) Remove the snap pin.
(2) Remove the shift fork pin and shift fork from the fulcrum
bridge.
6VD17. Fulcrum Bridge (6VD1)
(1) Remove the fulcrum bridge bolts.
(2) Remove the fulcrum bridge from the transmission case.
Important Operations - Installation
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.
3. Driven plate Assembly (HEC Engine Series)
2. Clutch Pressure Plate Assembly (HEC Engine Series)
(1) Clean the flywheel surface.
(2) Clean the facing surface.
(3) Use the clutch pilot aligner

1 to install the driven plate
assembly

2 to the flywheel
3.
Clutch Pilot Aligner : 5-8840-2634-0
(4) Clean the pressure plate surfaces.
(5) Align the pressure plate assembly

4 with the flywheel
knock pin

5.
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the
numerical order shown in the illustration.
Clutch Cover Bolt Torque N
m (kgfm/lbft)
17.6
4.9 (1.8 0.5/13.0 3.6)

7C-22 CLUTCH
Diaphragm Spring Finger Height
(Except 6VD1)
1. Place the appropriate spacer beneath the pressure plate.
Refer to the table below.
Spacer Thickness mm(in)
HEC, 4JG2T 8.0 (0.315)
4JA1, 4JB1T 7.8 (0.307)
2. Fully compress the pressure plate and the diaphragm
spring.
There are two ways to do this.
1) Use a bench press to press down the assembly from the
top.
2) Tighten the fixing bolts.
3. Measure the spring finger height

A from the base to the
spring tip.
Spring Finger Height mm(in)
HEC MSG 37-39
HEC MUA 39.9-41.9
4JA1 30.5-32.5 (1.20-1.28)
4JB1T 35.0-37.0 (1.38-1.46)
4JG2T 39.0-41.0 (1.53-1.61)
6VD1Diaphragm Spring Finger Height (6VD1)
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.
1) Use a bench press to press down on the assembly from
the top.
2) Tighten the fixing bolts.
NOTE: (6VD1)
Pre-load on diaphragm spring finger must be 49 - 98N (5.0
- 10.0 kg / 11 - 22 lb) in direction of release, when clutch
cover assembly is bolted to the flywheel.
3. Measure the spring height from base to spring tip
A.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Spring Finger Height mm(in)
Standard
6VD1 49.9-51.9 (1.965-2.043)

CLUTCH 7C-23
Release Bearing Replacement
Removal (Except 6VD1)
Use the bearing puller and the adapter to remove the release
bearing.
Bearing Puller : 5-8840-0013-0 (J-22888)
Adapter : 5-8840-0124-0 (J-2241-11)
Release Bearing Installation (Except 6VD1)
1. Set the release bearing to the shift block bearing fitting
surfaces.
The release bearing must be perfectly horizontal.
2. Use a bench press to fit the release bearing to the shift
block.
Install the parts as illustrated after applying wheel bearing
grease or multi-purpose type grease (NLGI No.2 or No.3).
6VD1Release Bearing (6VD1)
1. Visually check the release bearing for excessive play, noise
and breakage.
If any of these conditions are discovered, the release
bearing must be replaced.
6VD1NOTE:
When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.

7C-26 CLUTCH
Rivet Head Depression
Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression

1 from the facing surface
2.
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 facing
must be replaced.
Rivet Head Depression mm(in)
Standard
Fly wheel side P/Plate side
HEC 1.652.25
(0.065-0.089)
4JA1 1.351.95
(0.053-0.077)1.652.25
(0.065-0.089)0.2
(0.008)
4JB1T, 4JG2T 1.31.9
(0.051-0.075)
6VD1 1.6 (0.063)
Limit

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

CLUTCH 7C-47
Checkpoint Trouble Cause Countermeasure
Replace the driven plate
assemblyW arpage and/or uneven wear
Replace the driven plate
assemblyLoose facing rivets
NG NG OKDriven plate Continued from the previous page
FlywheelRepair or replace the flywheelFlywheel uneven wear NG OK