1997 ISUZU TFS SERIES Workshop Manual

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

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

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

7C-48 CLUTCH
4. CLUTCH NOISE
1) Clutch Pedal Depressed (Clutch Disengaged)
Checkpoint Trouble Cause Countermeasure
Replace the pedal shaft with
the sleeveW orn pedal shaft and/or
sleeve
Clean and grease the pedal
shaft and sleeveInsufficient grease at the
pedal shaft and sleeve
NG NGPedal shaft and sleeve
Master cylinder piston and
push rod contact facesClean and grease the master
cylinder piston and push rod
contact facesInsufficient grease at the
maser cylinder piston and
push rod contact faces NG OK
Driven plateReplace the driven plate
assemblyLoose or broken damper
spring NG OK
Crankshaft pilot bearingReplace the crankshaft pilot
bearingInsufficient grease at the
crankshaft pilot bearing (pilot
bearing worn) NG OK
2) Clutch Pedal Not Depressed (Clutch Engaged)
Replace the driven plateW eak or broken damper
spring NGDriven plate damper spring
Replace the crankshaft pilot
bearingInsufficient grease at the
crankshaft pilot bearing (pilot
bearing worn) OK
NG
Crankshaft pilot bearing

CLUTCH 7C-49
5. OIL LEAKAGE
Checkpoint Trouble Cause Countermeasure
Replace the piston capW eak or damaged piston cap NG
Tighten the oil pipe
Tighten the oil pipe connection
Tighten the fluid pipe and/or
hose connections
Fluid reservoirLoosely connected oil pipe
Loosely connected oil pipe
Master cylinder fluid pipe and
hoseLoosely connected fluid pipe
and/or hose
Slave cylinder oil pipe
Replace the piston cupSlave cylinderW eak or damaged piston cup
NG NG NG NG
OK OK
OK
OK
Master cylinder

7C-50 CLUTCH
SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-2634-0Clutch pilot aligner
(HEC Engine Series)
CLL-3
5-8840-0013-0
(J-22888)Bearing puller
(Except 6VD1 Engine)
CLL-4
5-8840-0124-0
(J-2241-11)Bearing puller adapter
(Except 6VD1 Engine)

TFCLU-WE-0005A AR
You are requested to order this manual using the
manual number that is shown above.
This manual is applicable for vehicles in all countries
except the USA, Canada, Europe and Thailand.
All rights reserved, This manual may not be
reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Mar., 2000 0003-01A-1

No. TFCLU-WE-0005A AR PRINTED IN JAPAN