2004 ISUZU TF SERIES clutch

CLUTCH 7C-45

2. CLUTCH DOES NOT RELEASE PROPERLY

Checkpoint Trouble Cause
Countermeasure


Adjust the push rod play

Too much push rod play in the
master cylinder
NG
Clutch pedal free play

Driven plate

Replace the driven plate

Driven plate warped or
unevenly worn


Hydraulic circuit

Bleed the hydraulic circuit

Air in the hydraulic circuit

OK
NG NG OK
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Corrosion or step wear on the
top gear shaft spline


Pressure plate

Replace the pressure plate
assembly


Clean and grease the splined
contact surface


Pressure plate unevenly worn

Insufficient grease on the
spline contact surface of the
splined hub
OK NG NG NG
OK
Continued on the next page

7C-46 CLUTCH

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

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-48 CLUTCH

Checkpoint Trouble Cause Countermeasure

Replace the driven plate
assemblyWarpage 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

CLUTCH 7C-49

4. CLUTCH NOISE

1) Clutch Pedal Depressed (Clutch Disengaged)

Checkpoint
Trouble Cause
Countermeasure

Replace the pedal shaft with
the sleeveWorn 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 plateWeak 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

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

CLUTCH 7C-51

SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME





5-85253-001-0

Clutch pilot aligner

7C-52 CLUTCH
MEMO