1997 ISUZU TFS SERIES Workshop Manual

10-40 CAB
JUMP SEAT
REMOVAL AND INSTALLATION
Removal Steps
1. Head rest and back trim cover
2. Hinge cover, center
3. Bolt
4. Jump seat assembly
Installation Steps
4. Jump seat assembly
3. Bolt
2. Hinge cover ; center
1. Head rest and back trim cover
Important Operation - Installation
3. Bolt
Torque N
m(kgfm/lbft)
19.6
5 (2 0.5 / 14.5 3.6)

CAB 10-41
JUMP SEAT BELT
REMOVAL AND INSTALLATION
Removal Steps
1. Hinge cover
2. Hinge cover ; center
3. Bolt
Installation Steps
3. Bolt
2. Hinge cover ; center
1. Hinge cover
Important Operation - Installation
3. Bolt
Torque N
m(kgfm/lbft)
39.2
9.8 (4 1 / 28.9 7.2)

WORKSHOP MANUAL
TF SERIES
CLUTCH
SECTION 7C

NOTICE
Before using this Workshop Manual to assist you in performing vehicle
service and maintenance operations, it is recommended that you
carefully read and thoroughly understand the information contained in
Section - OA under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.
All material contained in this Manual is based on the latest product
information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.

CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[ 7C- 2
General Description......................................................................................................... 7C-3
Torque Specification ...........................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-8
Servicing<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...... 7C- 13
Clut<0046004b0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[........ 7C- 15
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 7C- 15
Inspection and Repair................................................................................................. 7C- 20
Clutch Control .................................................................................................................. 7C- 27
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 7C- 27
Master Cylinder (Except 6VD1 Engine) .......................................................................... 7C- 30
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-30
Inspection and Repair................................................................................................. 7C- 31
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-32
Master Cylinder (6VD1 LHD Model) ................................................................................ 7C- 33
Disassembly and Reassembly ................................................................................... 7C- 33
Slave Cylinder (Except 6VD1 Engine) ............................................................................ 7C- 35
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-35
Inspection and Repair................................................................................................. 7C- 36
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-36
Hydraulic Damper Cylinder (Except 6VD1 Engine) ....................................................... 7C- 40
Inspection and Repair................................................................................................. 7C- 40
Troubleshooting .............................................................................................................. 7
C- 41
Special Service Tool ........................................................................................................ 7C-50
INDEX

7C-2 CLUTCH
MAIN DATA AND SPECIFICATIONS
ENGINEHEC Engine
Series with
MSG4JA1HEC Engine
Series with
MUA4JB1T 4JG2T 6VD1
Type Dry single plate with diaphragm
Size mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Clamping force kg(lb) 500 (1103) 500 (1103) 560 (1235) 640 (1411) 735 (1621)
(N) (4903) (4903) (5492) (6276) (7208)
Pressure plate
Outside diameter mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Inside diameter mm(in) 150 (5.906) 154 (6.063) 160 (6.299) 160 (6.299) 170 (6.70)
Driven plate
Thickness mm(in)
at free 8.4 (0.331) 8.6 (0.339) 8.0 (0.315) 8.2 (0.323) 8.3 (0.327)
at compressed 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 8.0 (0.315)
CLUTCH CONTROL LHD RHD
Type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Pedal height mm(in)
4JG2T 185.5-195.5 (7.30-7.70)
Others 178-188 (7.01-7.40) 216-226 (8.50-8.90)
Master cylinder
BoreStroke mm(in) 15.8735 (0.6251.38)
Slave cylinder
BoreStroke mm(in)
HEC Engine Series for
LHD/4JA120.6416 (0.8130.63)
HEC Engine Series for
RHD/4JB1T/4JG2T22.2215 (0.8750.59)
6VD1 22.2217 (0.8750.67)

CLUTCH 7C-3
GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE
HEC Engine Series4J Engine Series
6VD1
The clutch assembly consists of the pressure plate, the clutch cover, the diaphragm spring pivot pin and the driven
plate assembly.
The clutch pedal is connected to the shift block through the clutch shaft and the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
Diaphragm spring pressure holds the driven plate against flywheel and the pressure plate to provide the friction
necessary to engage the clutch.
Depressing the clutch pedal moves the shift fork against the shift block.
The shift block forces the release bearing against the diaphragm to overcome the force of the diaphragm spring and
separate the driven plate from the flywheel and pressure plate to disengage the clutch.
Except 6VD1 (3.2L) engine model, the conventional push-type clutch is used.
For 6VD1 (3.2L) engine model, the pull-type clutch is employed. The pull-type clutch is disengaged by pulling the
release lever (release bearing) to disengage the pressure plate.

7C-4 CLUTCH
MASTER CYLINDER
6VD1 LHD Model Except 6VD1 LHD Model
The master cylinder converts mechanical energy into hydraulic energy.
Depressing the clutch pedal causes the push rod to move against the piston to close the return port.
Clutch fluid is forced out of the master cylinder.
Releasing the clutch pedal causes the return spring to force the piston back to its original position.
The return port is opened and the clutch fluid flows back into the fluid reservoir.
Quickly releasing the clutch pedal will cause the fluid pressure at the return spring side to be lower than the fluid
pressure at the push rod side.
This allows the fluid at the push rod side to quickly flow to the return spring side through a port in the piston head.
This equalizes the pressure at both sides of the piston.