F70_F75_F77-CL-Clutch-Part1
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Service manual
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CLUTCH
CLUTCH PEDAL ADJUSTMENT CL- CLUTCH UNIT CL- COMPONENTS CL- TROUBLE SHOOTING CL- REMOVAL CL- INSPECTION CL- INSTALLATION CL- CLUTCH PEDAL & RELEASE CABLE CL-1
COMPONENTS CL-12
REMOVAL CL-1 INSPECTION (Clutch pedal & Release
cable) CL-1 WNSTALLATION CL-1 SSTs CL-1
SERVICE SPECIFICATIONS CL-19
TIGHTENING TORQUE CL-1
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CLUTCH
CLUTCH
The clutch mechanism employs a dry, single-disc, diaphragm spring type As for its operating method, lit
adopts a cable method which features positive
operation and excellent serviceability.
Pressure plate
Clutch disc specifications
Clutch disc outer diameter
T Natural aspiration vehicle J Turbo charger-equipped vehicle mml 240 I U
Ciutch disc inner diameter
I Pressure plate side
3.5
Lining surface area
Clutch cover specifications
Natura# aspiration vehicle I Turbo charger-equipped vehicle
Clutch cover outer diameter
Diaphragm spring load as assembled
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CLUTCH
U Following is ihe identification method for the clutch discs and clutch covers of F-70 (natural aspiration
vehicles.) and F-75 (turbo charger-equipped vehicles).
CLUTCH DISC
CLUTCH COVER
F70 (Natural Aspiration) I 7 f F75 (Turbo-charger-equipped) 7
WREB1-CL005
A: Identification marking position
Engine type
Natural Aspnation T Blue paint mark or equivalent 1 White paint mark or equivalent
Turbo charger-equipped Green paint mark or equivalent J Green paint mark or equivalent
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CLUTCH
CLUTCH PEDAL ADJUSTMENT 'T T
Check the clutch pedal for installation height. Pedal installation height NOTE: ~ Ensure that the clutch pedal installation height is 10.0 mm higher than the brake pedal surtace. Adjust the clutch pedal installation height, as required. Then, adjust the clutch pedal installation height to the following specification.
(Distance between pedal pad upper surface's center and dash panel)
Clutch Pedai Installation Height: L.H.D: 221 :Smm FLHD:
NOTE: - The figure above indicates the dimension from the body meta! section to the pedal. it is, therefore, necessary to roll up the carpet and floor mat prior to the measurement.
Adjust the pedal installation height, as required. (1) Slacken lhe lock nut. Turn the stopper bolt until the
installation height conforms to the specification. (2) Tighten the lock nut.
Tightening Torque:
17.7 - 29.4 N-m (1.8 - 3.0 kgf-m, 13.0 - 21.7 ft-lb)
Clutch pedal tree travel (1) Depress the clutch pedal gradually until you feel a resis
tance from the clutch. Measure the depressing distance up to this point. Specified Clutch Pedal Free Travel: 18 - 2? mm
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D If the free travel of the clutch pedal faiis to conform to the
specification, adjust it to the specified value by changing the
CLUTCH
A
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CLUTCH
CLUTCH UNIT
co|v|PoNENTs
14.7 - 24.5 I IE (1.5 - 25.108 -18.1)
'E11
G)
G) Clutch housing Release bea-ring hub clip
© Clutch re.-tease fork boot (it) Clutch release fork Ay
© Clutch release bearing hub SIA © Clutch cover SIA
Tightening Torque
Clutch disc Wave washer Release fork support SJA Tension spring
TROUBLE SHOOTING
Possible causes Remedies
Dragging clutch
- Excessfve free travel or clutch pedal _ . _
navel improperly adjusted Amus: iree travel or clutch pedal zraveis.
- Deiorrned clutch disc - Check clutch disc.
Clutch yudder ' .
spring heights
- Abnormal surface of clutch disc 1;- Check clutch disc.
- Excessive runoui of clutch disc -
Unevenness ofclutch cover diaphragm | -
Faulty clutch reiease bearmg -
- Clutch disc spline malfunqtioning Check clutch disc. - Abnormal surface of clutch disc Check clutch disc.
Check clutch disc rumour
Check clutch cover.
Check clgtch rglfaase bearing.
Worn clutch disc
Slipping clulch
Excessively worn clutch pressure plate | -
_ , - Faulty clutch cover diaphiagm springs
- Check clutch disc.
Check pressure plate.
- Check clutch cover. i
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CLUTCH
Following are the removal. inspection and installation proce- dures for the clutch pedal and release cable assembly. The procedures have been described Iypically for Model F-75. L.H.D. unit.
REMOVAL
1 Remove the transmission and transfer case assemblies from the vehicle. (For the removal procedure, see the MT section.) 2. Remove the clutch cover and ciutch disc: by removing the
six bolts.
3. Detach the clutch release fork boot from the clutch housing. 4, Remove the clutch re!ease fork, together with the clutch release bearing hub subassembly, by pulling the fork lightly toward you.
5. Remove me clutch housing with gasket by removing the
fou-r bolts. NOTE: - Never reuse the removed gasket
6 Slide the release bearing clip toward the section A. as indicated in the right figure. Detach the release bearing from the release fork, while lifting the hub clip lightly.
Replacement of type oil seal 1. Remove the "S" type oi! seal
NOTE: - Never reuse the removed oil seal
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CLUTCH
INSPECTION
1 Check the diaphragm spring for damage or wear.
2. Check of clutch disc for wear
Measure the height of the clutch disc from each rivet. Com
pare the lowest height against the allowable use limit below.
Allowable Use Limit: 0.3 mm
4. visuaiiy inspect the sliding surface of the clutch release fork
with the bearing hub. Check to see if any damage or wear | is nresent due to lack of cirease. / /I
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CLUTCH
5. Measure the section A of the clutch release fork (attaching
section of the clutch release support). Allowable Limit: 10 i 0.4 mm
Clutch release fork
$16 A
6. Rotate the release bearing with your fingers. Ensure that the
reiease bearing rotates smoothly without any binding. NOTE: v Since the release bearing is packed with grease, never
clean it. using oil.
7. Rotate the pilot bearing with your fingers. Prior to the instal- lation of the clutch disc. ensure that the pilot bearing rotates 5?'
2. Install the clutch cover. using the following SST. L -
SST: 09301-20020-000 093m_ _ . _ fi
CAUTION:
sequence.)
sequence.) 5 ., 3 check me dia f' f ' " - /
. pgragm spnng mgers or unevenness 5. 4 height, using the following SST. Aliowable Limit of Unevenness in Height: 0.8 mm
SST: 09388-87702-000 f
