Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1040

CLUTCH  7C-19

6VD1

(2) Install the release bearing in the proper direction.

3. Driven Plate Assembly (Except HEC Engine Series)

Use the pilot aligner to install the driven plate assembly.

Pilot aligner: 5-8525-3001-0 (J-24547)

6VD1

2. Pressure Plate Assembly (6VD1)

(1) Tighten the bolts holding the pressure plate assembly in the

order shown in illustration.

Pressure Plate Bolt Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

20.6

±

2.9 (2.1

±

0.3/15.2

±

2.2)

(2) Remove the aligner.

NOTE:

Do not strike the aligner with a hammer to remove it.

1. Transmission Assembly

7C-20  CLUTCH

  INSPECTION AND REPAIR

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

PRESSURE PLATE ASSEMBLY

Visually inspect the pressure plate friction surface for
excessive wear and heat cracks.
If excessive wear or deep heat cracks are present, the
pressure plate must be replaced.

Pressure Plate Warpage

Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the
pressure plate must be replaced.
Pressure Plate Warpage

mm(in)

Limit

0.3 (0.012)

Clutch Cover

Visually inspect the entire clutch cover for excessive wear,
cracking , and other damage.
The clutch cover must be replaced if any of these conditions
are present.

1. Abrasion, scratches, cracks and deflection of friction face to

the disc, loose rivet and wear of ring

•

Grind small scratches, or replace the assembly if extreme

scratches are found.

CLUTCH  7C-21

Clutch Set Force (Except 6VD1)

1. Position the pressure plate assembly 

1

 as shown in the

illustration.

2. Place the new driven plate 

2

 over the pressure plate

assembly.

Driven Plate Thickness (Reference)

mm(in)

Standard

Free

Compressed

HEC (MSG)

8.4 (0.330)

8.0 (0.315)

HEC (MUA)

8.6 (0.338)

8.0 (0.315)

4JG2T

8.2 (0.323)

8.0 (0.315)

4JA1

8.0 (0.315)

7.8 (0.307)

4JB1T

8.0 (0.315)

7.8 (0.307)

3. Place a metal sheet 

3

 between the press and the driving

plate.

4. Compress the metal sheet and the driven plate until the

driven plate is flush with the drive plate assembly 

A

.

5. Note the pressure gauge reading.

Driven Plate Slamping Force

N (kg/Ib)

Standard

HEC (MSG), 4JA1

4,903 (500/1,103)

HEC (MUA), 4JB1T

5,492 (560/1,235)

4JG2T

6,276 (640/1,411)

Clutch Set Force (6VD1)

1. Invert the pressure plate assembly.

2. Place a new driven plate over the pressure plate.

A metal sheet with 

A

 thickness of 8.0 mm (0.315 in) may

be used in place of the driven plate.

3. Compress the pressure plate assembly until the distance 

B

becomes 12 mm (0.472 in).

4. Note the pressure gauge reading.

If the measured value is less than the specified limit, the

pressure plate assembly must be replaced.

Clutch Set Force

N (kg/Ib)

Standard

Limit

6VD1

7,208 (735/1,621)

6,669 (680/1,499)

7C-22  CLUTCH

Diaphragm Spring Finger Height

(Except 6VD1)

1. Place the appropriate spacer beneath the pressure plate.

Refer to the table below.

Spacer Thickness

mm(in)

HEC, 4JG2T

8.0 (0.315)

4JA1, 4JB1T

7.8 (0.307)

2. Fully compress the pressure plate and the diaphragm

spring.

There are two ways to do this.

1) Use a bench press to press down the assembly from the

top.

2) Tighten the fixing bolts.

3. Measure the spring finger height 

A

 from the base to the

spring tip.

Spring Finger Height

mm(in)

HEC MSG

37-39

HEC MUA

39.9-41.9

4JA1

30.5-32.5 (1.20-1.28)

4JB1T

35.0-37.0 (1.38-1.46)

4JG2T

39.0-41.0 (1.53-1.61)

6VD1

Diaphragm Spring Finger Height (6VD1)

1. Place a new driven plate or a 8.0 mm (0.315 in) spacer

beneath the pressure plate.

2. Fully compress the pressure plate and diaphragm spring.

There are two ways to do this.

1) Use a bench press to press down on the assembly from

the top.

2) Tighten the fixing bolts.

NOTE: (6VD1)

Pre-load on diaphragm spring finger must be 49 - 98N (5.0
- 10.0 kg / 11 - 22 lb) in direction of release, when clutch
cover assembly is bolted to the flywheel.

3. Measure the spring height from base to spring tip 

A

.

If the measured value exceeds the specified limit, the

pressure plate assembly must be replaced.

Spring Finger Height

mm(in)

Standard

6VD1

49.9-51.9 (1.965-2.043)