Page 4817 of 6020

CLUTCH 7C-39
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
RTW 77CSH000901
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.
206RS004
Piston and Piston Cup
1. Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
2. Replace the inner parts with new parts shown in the illustration.
206RS005
3. Measure the clearance between slave cylinder wall and
piston.
4. If the measured value exceeds the specified limit, the slave cylinder assembly must be replaced.
mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.006)
Clutch Damper Valve
1. Visually inspect the entire clutch damper valve housing or
connector for cracking and other damage.
The slave cylinder assembly must be replaced if any o
f
these conditions are present.
2. Measure resistance between terminals.
Replace slave cylinder assembly if less than standard value.
Standard: 14.3 Ω
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 4818 of 6020
7C-40 CLUTCH
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:
RTW 77CSH001001
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the front of cylinder. Use care so as not to scratch the cylinder.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 4819 of 6020
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.
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 4820 of 6020
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
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 4821 of 6020
CLUTCH 7C-43
1. CLUTCH SLIPPAGE
Checkpoint Problem 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
Release bearing
NG
NG
NG
OK
OK OK
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 4822 of 6020
7C-44 CLUTCH
Checkpoint Problem 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 assemblyW eak or broken clutch
diaphragm spring
Replace the driven plate
assemblyWorn facing
NG
NG
OKFacing
Continued from the previous page
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 4823 of 6020
CLUTCH 7C-45
2. CLUTCH DOES NOT RELEASE PROPERLY
Checkpoint Problem 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
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007
Page 4824 of 6020
7C-46 CLUTCH
Checkpoint Problem 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
BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007