Page 4809 of 6020

CLUTCH 7C-31
Driven Plate Warpage
1. Insert the clutch pilot aligner into the driven plate splinedhub.
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 W arpage mm(in)
Standard Limit
0.7 (0.028)1.0 (0.039)
Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft spline.
3. Set a surface gauge to the driven plate outside circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven plate.
If the measured value exceeds the specified limit, the driven plate assembly must be replaced.
Driven Plate Splined Hub Spline W ear mm(in)
Standard Limit
0.5 (0.020)1.0 (0.039)
Rivet Head Depression
Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression
1 from the facing surface
2.
Be sure to measure the rivet head depression on both sides of
the driven plate.
If the measured value is less than the specified limit, the facing
must be replaced.
Rivet Head Depression mm(in)
Standard
Fly wheel side P/Plate side Limit
4J
series 1.35-1.95
(0.053-0.077) 1.65-2.25
(0.065-0.089) 0.2
(0.008)
C24SE 1.65-2.25
(0.065-0.089) 1.65-2.25
(0.065-0.089) 0.2
(0.008)
4JJ1
(High Output)
1.40-2.00
(0.055-0.079) 1.70-2.30
(0.067-0.091) 0.2
(0.008)
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Page 4810 of 6020
7C-32 CLUTCH
CLUTCH CONTROL
REMOVAL AND INSTALLATION
RTW 77CLF000601
Removal Steps
1. Pin
2. Jaw joint pin
3. Pedal assembly
4. Oil line
5. Master cylinder assembly
6. Oil line
7. Slave cylinder assembly
8. Damper cylinder assembly
Installation Steps
8. Damper cylinder assembly
7. Slave cylinder assembly
6. Oil line
5. Master cylinder assembly
4. Oil line
3. Pedal assembly
2. Jaw joint pin
1. Pin
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ISUZU KB P190 2007
Page 4811 of 6020
CLUTCH 7C-33
MASTER CYLINDER
DISASSEMBLY
Disassembly Steps
1. Bolt : reservoir tank
2. Reservoir tank
3. Yoke
4. Lock nut
5. Body sub assembly
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ISUZU KB P190 2007
Page 4812 of 6020
7C-34 CLUTCH
REASSEMBLY
Reassembly Steps
1. Body sub assembly
2. Lock nut
3. Yoke
4. Reservoir tank
5. Bolt : Reservoir Tank
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ISUZU KB P190 2007
Page 4813 of 6020
CLUTCH 7C-35
SLAVE CYLINDER (MSG, MUA)
DISASSEMBLY
Disassembly Steps
1. Boot
2. Push rod
3. Piston and piston cup
4. Spring
5. Cylinder body
Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.
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ISUZU KB P190 2007
Page 4814 of 6020
7C-36 CLUTCH
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.
Cylinder Bore and piston Clearance
1. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. Calculate the clearance between the cylinder bore and the piston diameter.
If the clearance exceeds the limit, the entire slave cylinde
r
assembly must be replaced.
Cylinder Bore and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028)0.15 (0.006)
Piston and Piston Cup
Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts (Repair kit A) shown in
the illustration.
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ISUZU KB P190 2007
Page 4815 of 6020
CLUTCH 7C-37
REASSEMBLY
Reassembly Steps
1. Cylinder body
2. Spring
3. Piston and piston cup
4. Push rod
5. Boot
Important Operations
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.
3. Piston and piston Cup
1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the illustration.
3) Install the piston and piston cup to the cylinder body.
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ISUZU KB P190 2007
Page 4816 of 6020
7C-38 CLUTCH
SLAVE CYLINDER (MUX)
DISASSEMBLY
RTW 77CSF000501
Disassembly Steps
1. Push rod
2. Boot
3. Piston and piston cup
4. Spring
5. Cylinder body
6. Clutch damper valve
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ISUZU KB P190 2007