2004 ISUZU TF SERIES check oil

7C-30 CLUTCH


Shift Fork
1. Visually inspect the surfaces of the shift fork making contact
with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from the release
bearing with an oil stone.
Replace any exhibiting excessive wear or damage.
3. Apply multi-purpose type grease (NLGI No.2 or No.3) to
area.



DRIVEN PLATE ASSEMBLY
1. Visually inspect the torsion spring
1 for looseness,
breakage, and weakening.
If any of these conditions are discovered, the driven plate
assembly must be replaced.



2. Visually inspect the facing surfaces
2 for cracking and
excessive scorching.

Visually inspect the facing surfaces for the presence of oil
or grease.
If any of these conditions are discovered, the facing mus
t
be cleaned or replaced.



3. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed
with an oil stone.



Driven Plate Warpage
1. Insert the clutch pilot aligner into the driven plate splined
hub.
The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner : 5-8525-3001-0
2. Set a dial indicator to the driven plate outside
circumference.
3. Slowly turn the driven plate.
Read the dial indicator as you turn the driven plate.
If the measured value exceeds the specified limit, the driven
plate assembly and/or the facing must be replaced.
Driven Plate Warpage mm(in)
Standard Limit
0.7 (0.028) 1.0 (0.039)

CLUTCH 7C-41
HYDRAULIC DAMPER CYLINDER
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




Visually check for oil leakage and other damage.
If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.

7C-42 CLUTCH

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage

CLUTCH 7C-43

1. CLUTCH SLIPPAGE

Checkpoint
Trouble Cause
Countermeasure


Adjust the push rod play

No push rod play in the master
cylinder
NG
Clutch pedal free play

Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal

Clean the related parts and/or
replace the facing


Repair or replace the
transmission front cover


Defective transmission front
cover oil seal

Continued on the next page

Grease or oil adhering to the
facing

Too much grease


Transmission front cover
unevenly worn


Clean and grease the release
bearing

Release bearing

Insufficient grease on the front
cover contact surfaces

NG NG NG NG OK
OK
OK

7C-44 CLUTCH

Checkpoint Trouble Cause Countermeasure

Replace the release bearingRelease bearing broken
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Defective crankshaft rear oil
seal
NG NG
OK OKGrease or oil adhering to the
facing
Clutch diaphragm springReplace the clutch pressure
plate assemblyWeak or broken clutch
diaphragm spring
Replace the driven plate
assemblyWorn facing
NG NG
OKFacing Continued from the previous page

CLUTCH 7C-47

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

7C-50 CLUTCH

5. OIL LEAKAGE

Checkpoint
Trouble Cause
Countermeasure


Replace the body sub
assembly
Weak or damaged piston cup
NG

Tighten the oil pipe


Tighten the oil pipe connection


Tighten the fluid pipe and/or
hose connections


Fluid reservoir

Loosely connected oil pipe


Loosely connected oil pipe


Master cylinder fluid pipe and
hose

Loosely connected fluid pipe
and/or hose


Slave cylinder oil pipe


Replace the piston cup

Slave cylinder

Weak or damaged piston cup

NG NG NG NG
OK OK
OK
OK

Master cylinder

ELECTRICAL-BODY AND CHASSIS 8A-25
Light Name Rated Power
V-W Number of
Bulbs Lens
Color Remarks
W/O Tacho 5Illumination light 14-2
W/ Tacho 7White
Turn Signal 14-1.12 2 Green
High Beam 14-1.12 1 Blue
Low Fuel 14-1.12 1 Amber
A/T Oil Temp 14-1.12 1 Red
Brake system 14-1.12 1 Red
4WD 14-1.12 1 Green
Seat belt 14-1.12 1 Red
Oil pressure 14-1.12 1 Red
ABS 14-1.12 1 Amber
SEDIMENTER 14-1.12 1 Red
AIR BAG 14-1.12 1 Red
Brake 14-1.12 1 Red
Charge 14-1.12 1 Red
Check Trans 14-1.12 1 Red
Check 4WD 14-1.12 1 Red
Power drive 14-1.12 1 Amber
3rd start 14-1.12 1 Green
4L 14-1.12 1 Green
Cruise Set 14-1.12 1 Green
Check Engine 14-1.12 1 Amber
Front Fog 14-1.12 1 Green
Rear foglight 14-1. 12 1 Amber
Glow 14-1.12 1 Amber
P LED 1 Green
R LED 1 Green
N LED 1 Green
D LED 1 Green
3 LED 1 Green
2 LED 1 Green












Indicator/
Warning
light
A/T shift
indicator
L LED 1 Green