2004 ISUZU TF SERIES clutch

4C2-8 SHIFT ON THE FLY SYSTEM



RTW440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, or
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as soothlessness when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.




RTW440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)



RTW440SH000501



RTW440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.
State Port 3Port 4Port 1, 2
Conducting Function
A






C
B







D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.

4C2-10 SHIFT ON THE FLY SYSTEM



412RS044





















13. Inner Shaft Bearing


Place a new snap ring in inner shaft.


Force a new inner shaft bearing into the inner shaft.
Installer : 5-8840-2197-0 (J-37452)


12. Snap Ring
NOTE;
Be careful not to damage the inner shaft.

11.inner Shaft


Clean the housing contact surface of the front axle
case.


Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.




412RW017

10. Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.


9. Clutch Gear
Apply differential gear oil to clutch oil.
8. Sleeve
Apply differential gear oil to sleeve.




412RW023


7. Housing


Clean contact surface with the front axle and sctuator
mounting surface.

Apply liquid gasket to the contact surface on the front
axle case and install in the housing.

6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque N m (kg m/lb ft)
75 (7.6/55)

5A-42 BRAKE CONTROL SYSTEM

Braking Sound (From EHCU) Is Heard While Not Braking

Step Action Value(s) Yes No
1 Is this the first vehicle start after engine start?
- It is self
checking
sound
Normal. Go to Step 2
2 Is vehicle speed under 10 km/h?
- It is self
checking
sound
Normal. Go to Step 3
3 Check for the following condition:
 At the time of shift down or clutch operation.
 At the time of low road friction drive (ice or snow
road) or rough road drive.
 At the time of high-speed turn.
 At the time of passing curb.
 At the time of operating electrical equipment
switches.
 At the time of racing the engine.
Did it occur under any one condition above?
- ABS may
sometimes be
actuated even
when brake
pedal is not
applied. Go to Step 4
4 Is there play in each or any sensor/wheel speed
sensor rotor?
- Repair.
Go to Step 7 Go to Step 5
5 Damage or powdered iron sticking to each or any
sensor/wheel speed sensor rotor?
- Repair.
Go to Step 7 Go to Step 6
6 Is each sensor normal?
Note : Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2WD or 4WD Model)

- Check
harness/
connector for
suspected
disconnection
If no
disconnection
is found,
replace EHCU
Go to Step 7 Repair.
Go to Step 7
7 Reconnect all components, ensure all components
are properly mounted.
Was this step finished?
- Repeat the
“Basic
diagnostic
flow chart” Go to Step 7

WORKSHOP MANUAL

TF SERIES




CLUTCH






SECTION 7C

CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 7C- 2
General Description......................................................................................................... 7C- 3
Torque Specification ....................................................................................................... 7C-15
Servicing........................................................................................................................... 7C-19
Clutch................................................................................................................................ 7C-21
Removal and Installation ............................................................................................ 7C-21
Inspection and Repair................................................................................................. 7C-26
Clutch Control .................................................................................................................. 7C-32
Removal and Installation ............................................................................................ 7C-32
Master Cylinder ................................................................................................................ 7C-33
Disassembly ................................................................................................................ 7C-33
Reassembly ................................................................................................................. 7C-34
Slave Cylinder (4J, C24SE) ............................................................................................. 7C-35
Disassembly ................................................................................................................ 7C-35
Inspection and Repair................................................................................................. 7C-36
Reassembly ................................................................................................................. 7C-37
Slave Cylinder (6VE1) ...................................................................................................... 7C-38
Disassembly ................................................................................................................ 7C-38
Inspection and Repair................................................................................................. 7C-39
Reassembly ................................................................................................................. 7C-40
Hydraulic Damper Cylinder ............................................................................................. 7C-41
Inspection and Repair................................................................................................. 7C-41
Troubleshooting .............................................................................................................. 7C-42
Special Service Tool ........................................................................................................ 7C-51

7C-2 CLUTCH
MAIN DATA AND SPECIFICATIONS
ENGINE 6VE1
4JA1-T(L) 4JA1-TC
4JH1-TC C24SE
Clutch type Dry single plate with diaphragm
Size mm (in)260 (10.24) 225 (8.86) 250 (9.84) 240 (9.45)
Clamping force kg(lb)735 (1621) 500 (1103) 640 (1411) 560 (1235)
(N)(7200) (4900) (6300) (5500)
Pressure plate
Outside diameter mm(in)260 (10.24) 225 (8.86) 250 (9.84) 240 (9.45)
Inside diameter mm(in)170 (6.69) 150 (5.906) 160 (6.299) 160 (6.299)
Driven plate
Thickness mm(in)
at free 8.8 (0.346) 8.4 (0.331) 8.3 (0.327) 8.7 (0.342)
at compressed 8.2 (0.323) 7.8 (0.307) 7.8 (0.307) 8.0 (0.315)
Clutch Cont. type Hydraulic
Pedal free play mm(in)5.0-15.0 (0.2-0.6)
Master cylinder
Bore

Stroke mm(in)15.87

35 (0.625

1.38)
Slave cylinder
Bore

Stroke mm(in)22.22

18.9
(0.875

0.744) 19.05

23
(0.749

0.906) 20.64

23
(0.813

0.906) 19.05

23
(0.749

0.906)

CLUTCH 7C-3
GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE
PUSH TYPE CLUTCH (4J C24SE)



PULL TYPE CLUTCH (6VE1)
A07RW046

7C-4 CLUTCH
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 release bearing through the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
For 4J series engine and HEC engine models, the push-type clutch is used.
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 release bearing.
The release bearing forces 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.
For 6VE1 engine model, the pull-type clutch is used. The pull-type clutch is disengaged by pulling the release lever
(release bearing) to disengage the pressure plate.