Mitsubishi L200. Manual - part 239

21B-1

GROUP 21B

CLUTCH 

OVERHAUL

CONTENTS

GENERAL SPECIFICATIONS . . . . . .

21B-2

SERVICE SPECIFICATIONS. . . . . . .

21B-2

TORQUE SPECIFICATIONS . . . . . . .

21B-2

LUBRICANTS  . . . . . . . . . . . . . . . . . .

21B-2

CLUTCH . . . . . . . . . . . . . . . . . . . . . . .

21B-3

CLUTCH REMOVAL AND INSTALLATION  

21B-3

CLUTCH INSPECTION . . . . . . . . . . . . . . . . 

21B-5

CLUTCH RELEASE CYLINDER  . . . .

21B-6

CLUTCH RELEASE CYLINDER DISASSEMBLY AND 
REASSEMBLY  . . . . . . . . . . . . . . . . . . . . . . 

21B-6

CLUTCH RELEASE CYLINDER INSPECTION

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21B-7

GENERAL SPECIFICATIONS

CLUTCH OVERHAUL

21B-2

GENERAL SPECIFICATIONS

M1212000201356

Item

R5MB1-J-ND1

R5MB1-J-NC,V5MB1

Clutch operating method

Hydraulic type

Clutch disc type

Single dry disc type

Clutch disc size O.D. 

× I.D. mm

225 

× 150

250 

× 160

Clutch cover type

Diaphragm spring type

Clutch cover setting load N

5,394 

± 441

5,850 

± 470

SERVICE SPECIFICATIONS

M1212000300286

Item

Limit

Diaphragm spring end height difference mm

0.5

Facing rivet sink mm

0.3

Release cylinder I.D. to piston O.D. clearance mm

0.15 

TORQUE SPECIFICATIONS

M1212001800347

Item

N

⋅m

Fulcrum

35 

± 6

Clutch release cylinder mounting bolt

35 

± 6

Clutch cover mounting bolt

19 

± 3

Air bleeder

8.0 

± 1.0

LUBRICANTS

M1212000400681

Items

Specified lubricants

Quantity

Clutch release bearing to release fork 
contact surface

Mitsubishi Part No. 0101011 or equivalent

As required

Fulcrum to release fork contact surface
Clutch release cylinder push rod to release 
fork contact surface
Clutch release bearing inside
Clutch disc spline
Clutch release cylinder inner surface

Brake Fluid DOT 3 or DOT 4

Piston and piston cups outer surface

Rubber grease

CLUTCH

CLUTCH OVERHAUL

21B-3

CLUTCH

DISASSEMBLY AND REASSEMBLY

M1212001001065

AK403591

1

2

3

4

5

6

7

3

35 ± 6 N·m

19 ± 3 N·m

35 ± 6 N·m

8

AB

Removal steps 

>>

C

<<

1.

Clutch cover

>>

C

<<

2.

Clutch disc

3.

Return clip

>>

B

<<

4.

Clutch release bearing

5.

Clutch release cylinder

6.

Boot

<<

A

>>

>>

A

<<

7.

Release fork

8.

Fulcrum

DISASSEMBLY SERVICE POINT

<<A>> RELEASE FORK REMOVAL

AK403602 AB

Fulcrum

Release fork

Clip

Slide the release fork in direction of the arrow and 
disengage the fulcrum from the clip to remove the 
release fork. Be careful not to damage the clip by 
pushing the release fork in the wrong direction or 
removing it with force.

CLUTCH

CLUTCH OVERHAUL

21B-4

REASSEMBLY SERVICE POINTS

>>A<< RELEASE FORK INSTALLATION

AK403592AB

Fulcrum

Release fork

Clutch release cylinder

1. Apply the specified grease to the release fork.

Specified grease: Mitsubishi Part No. 
0101011 or equivalent

2. Install the release fork onto the fulcrum.

>>B<< CLUTCH RELEASE BEARING 
INSTALLATION

AK503501AB

1. Apply the specified grease to the clutch release 

bearing inside, and fill grease in the groove.

Specified grease: Mitsubishi Part No. 
0101011 or equivalent

2. Install the clutch release bearing on the bearing 

retainer of the transmission.

3. Install the return clip to engage the clutch release 

bearing with the fork.

>>C<< CLUTCH DISC / CLUTCH COVER 
INSTALLATION

AK403594

Clutch disc

Flywheel

Clutch cover

Clutch disc guide

AB

1. Apply the specified grease to the clutch disc 

splines and rub it in splines with a brush.

Specified grease: Mitsubishi Part No. 
0101011 or equivalent

2. Using the clutch disc guide to position the clutch 

disc on the flywheel.

AK500601

1

5

4

2

3

7

8

6

Dowel pin 
position

:

AE

3. Install the clutch cover, aligning its installation 

position with the dowel pins, and then tighten the 
bolts to the specified torque of 19 

± 3 N⋅m in the 

order shown in the illustration.