Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1035

WORKSHOP MANUAL

TF SERIES

CLUTCH

SECTION 7C

NOTICE

Before using this Workshop Manual to assist you in performing vehicle

service and maintenance operations, it is recommended that you

carefully read and thoroughly understand the information contained in

Section - OA under the headings “GENERAL REPAIR

INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on the latest product

information available at the time of publication.

All rights are reserved to make changes at any time without prior

notice.

CLUTCH  7C-1

SECTION 7C

CLUTCH

TABLE OF CONTENTS

PAGE

Main Data and Specifications ......................................................................................... 7C- 2

General Description......................................................................................................... 7C- 3

Torque Specification ....................................................................................................... 7C- 8

Servicing........................................................................................................................... 7C- 13

Clutch................................................................................................................................ 7C- 15

Removal and Installation ............................................................................................ 7C- 15

Inspection and Repair................................................................................................. 7C- 20

Clutch Control.................................................................................................................. 7C- 27

Removal and Installation ............................................................................................ 7C- 27

Master Cylinder (Except 6VD1 Engine) .......................................................................... 7C- 30

Disassembly ................................................................................................................ 7C- 30

Inspection and Repair................................................................................................. 7C- 31

Reassembly ................................................................................................................. 7C- 32

Master Cylinder (6VD1 LHD Model) ................................................................................ 7C- 33

Disassembly and Reassembly ................................................................................... 7C- 33

Slave Cylinder (Except 6VD1 Engine) ............................................................................ 7C- 35

Disassembly ................................................................................................................ 7C- 35

Inspection and Repair................................................................................................. 7C- 36

Reassembly ................................................................................................................. 7C- 36

Hydraulic Damper Cylinder (Except 6VD1 Engine) ....................................................... 7C- 40

Inspection and Repair................................................................................................. 7C- 40

Troubleshooting .............................................................................................................. 7C- 41

Special Service Tool........................................................................................................ 7C- 50

INDEX

7C-2  CLUTCH

MAIN DATA AND SPECIFICATIONS

ENGINE

HEC Engine

Series with

MSG

4JA1

HEC Engine

Series with

MUA

4JB1T

4JG2T

6VD1

Type

Dry single plate with diaphragm

Size

mm(in) 215 (8.465)

225 (8.858)

240 (9.449)

250 (9.843)

260 (10.24)

Clamping force

kg(lb)

500 (1103)

500 (1103)

560 (1235)

640 (1411)

735 (1621)

(N)

(4903)

(4903)

(5492)

(6276)

(7208)

Pressure plate

Outside diameter

mm(in) 215 (8.465)

225 (8.858)

240 (9.449)

250 (9.843)

260 (10.24)

Inside diameter

mm(in) 150 (5.906)

154 (6.063)

160 (6.299)

160 (6.299)

170 (6.70)

Driven plate

Thickness

mm(in)

at free

8.4 (0.331)

8.6 (0.339)

8.0 (0.315)

8.2 (0.323)

8.3 (0.327)

at compressed

8.0 (0.315)

7.8 (0.307)

8.0 (0.315)

7.8 (0.307)

8.0 (0.315)

8.0 (0.315)

CLUTCH CONTROL

LHD

RHD

Type

Hydraulic

Pedal free play  mm(in)

5.0-15.0 (0.2-0.6)

Pedal height  mm(in)

4JG2T

185.5-195.5 (7.30-7.70)

−

Others

178-188 (7.01-7.40)

216-226 (8.50-8.90)

Master cylinder

Bore

×

Stroke

mm(in)

15.87

×

35 (0.625

×

1.38)

Slave cylinder

Bore

×

Stroke

mm(in)

HEC Engine Series for

LHD/4JA1

20.64

×

16 (0.813

×

0.63)

HEC Engine Series for

RHD/4JB1T/4JG2T

22.22

×

15 (0.875

×

0.59)

6VD1

22.22

×

17 (0.875

×

0.67)