Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1043

CLUTCH  7C-31

  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 if

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 cylinder

assembly must be replaced.

Cylinder Bore and Piston Clearance

mm(in)

Standard

Limit

0.07 (0.0028)

0.15 (0.006)

Inner Parts

Replace the inner parts with new parts shown in the illustration.

7C-32  CLUTCH

  REASSEMBLY

* Apply grease

(COSMO rubber grease)

★

 Repair Kit

Reassembly Steps

▲

1. Cylinder body
2. Piston and assembly
3. Push rod
4. Stopper
5. Stopper ring

6. Dust cover
7. Lock nut
8. Joint
9. Oil tank assembly

10. Oil tank band

Important Operations

1. Cylinder Body
Immerse the cylinder body in clean brake fluid.

CLUTCH  7C-33

Master Cylinder (6VD1 LHD Model)

 

  DISASSEMBLY AND REASSEMBLY

Disassembly Steps

1. Reservoir cap
2. Base cap
3. Seal
4. Clip
5. Reservoir
6. Gasket
7. Yoke
8. Nut
9. Rod stopper

10. Push rod
11. Piston assembly
12. Plate
13. O-ring
14. Damper ring
15. Diaphragm
16. Seal ring
17. Cylinder body

Reassembly Steps

To reassemble, follow disassembly
steps in the reverse order.

Disassembly

1. Disassemble reservoir cap 1., base cap 2., seal

3., clip 4., and reservoir 5..

2. Disassembly gasket 6., yoke 7., and nut 8..
3. Disassemble rod stopper 9., push rod 10., and

piston assembly 11..

4. Disassemble plate 12., o-ring 13., damper ring

14., diaphragm 15., and seal ring 16. from
cylinder body 17..

7C-34  CLUTCH

Inspection and Repair

Make the necessary adjustments, repair, 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 if necessary.

Inner Parts

1. Visually inspect the disassembled parts for

excessive wear and damage.

Replace the inner parts with new parts shown in the

illustration.

2. Measure the clearance between master cylinder

wall and piston.

If the measured value exceeds the specified limit,

the master cylinder assembly must be replaced.

Standard: 0.07 mm (0.0028 in)

Limit: 0.15 mm (0.0059 in)

Reassembly

To reassemble, follow the disassembly steps in the
reverse order, noting the following points:

Cylinder Body

Immerse the cylinder body in clean brake fluid.

Piston Assembly

Before installing, apply a thin coat of rubber grease to
the piston. Install cup in groove in piston with lip turned
to front of cylinder. Use care to prevent damaging the
lip of the piston seat.