21B-0-1

CLUTCH
F5M41, F5M42, W5M42
CONTENTS

1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B-1-1
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B-1-1
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B-1-1
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B-1-2
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B-1-2
2. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B-2-1
3. CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B-3-1

E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised

21B-0-2
NOTES

E Mitsubishi Motors Corporation Nov. 1995 PWEE9508-A Added

 CLUTCH – Specifications 21B-1-1
1. SPECIFICATIONS
GENERAL SPECIFICATIONS
Items F5M41-4G13, 4G15 F5M41-4G92 F5M42-4G92

Clutch operating method Hydraulic type Hydraulic type Hydraulic type

Clutch disc type Single dry disc type Single dry disc type Single dry disc type

Clutch disc size O.D. x I.D. mm 184 x 127 200 x 130 215 x 140

Clutch cover type Diaphragm spring type Diaphragm spring type Diaphragm spring type

Clutch cover setting load N 3256 4193 4539

Clutch release cylinder I.D. mm 20.64 20.64 20.64

Items F5M42-4G93, 4G94, F5M42-4G63, 4G64, F5M42-6A13

4G63 6A12, 4D68

Clutch operating method Hydraulic type Hydraulic type Hydraulic type

Clutch disc type Single dry disc type Single dry disc type Single dry disc type

Clutch disc size O.D. x I.D. mm 215 x 140 225 x 150 225 x 150

Clutch cover type Diaphragm spring type Diaphragm spring type Diaphragm spring type

Clutch cover setting load N 4511 4511 5198

Clutch release cylinder I.D. mm 20.64 20.64 20.64

Items F5M51 F5M42-4G64-GDI, F5M42-4G94

W5M42

Clutch operating method Hydraulic type Hydraulic type Hydraulic type

Clutch disc type Single dry disc type Single dry disc type Single dry disc type

Clutch disc size O.D. x I.D. mm 225 x 150 230 x 155 215 x 140

Clutch cover type Diaphragm spring type Diaphragm spring type Diaphragm spring type

Clutch cover setting load N 5864 5200 4510

Clutch release cylinder I.D. mm 20.64 20.64 –

SERVICE SPECIFICATIONS
Items Specifications (limit)

Clutch disc facing rivet sink mm 0.3

Diaphragm spring end height difference mm 0.5

<F5M41, F5M42, W5M42>

Release cylinder I.D. to piston O.D. clearance mm 0.15

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

21B-1-2 CLUTCH – Specifications

TORQUE SPECIFICATIONS
Items Specified torque

Clutch damper mounting bolt Nm <F5M41, F5M42, W5M42> 18

Clutch fluid line bracket Nm 18

Clutch release cylinder air bleeder Nm <Except clutch release concentric cylinder> 17

Clutch release cylinder air bleeder Nm <Clutch release concentric cylinder> 11

Clutch release cylinder mounting bolt Nm <F5M41, F5M42, W5M42> 18

Clutch release cylinder union bolt Nm 22

Clutch tube flare nut Nm 15

Clutch release cylinder and clutch damper mounting bolt Nm <F5M51> 18

Fulcrum Nm <F5M41, F5M42, W5M42> 35

Release fork shaft mounting bolt Nm <F5M51> 9.8

LUBRICANTS
Items Specified lubricants

Release fork and fulcrum contact surface MITSUBISHI genuine grease Part No. 0101011 or
<F5M41, F5M42, W5M42> equivalent

Release fork and release bearing contact surface

Release fork and release cylinder push rod contact surface

Release fork and release fork shaft contact surface <F5M51>

Piston and piston cup outer surface Brake fluid SAE J1703 (DOT3)

Release cylinder inner surface

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

 CLUTCH – Clutch 21B-2-1
2. CLUTCH
REMOVAL AND INSTALLATION <F5M41>

18 Nm

2
1

35 Nm
15 14
9 12

10
4
5
13
22 Nm
11
7

15 Nm
18 Nm

18 Nm
8

Removal steps
1. Clutch fluid line bracket 9. Clutch cover
2. Insulator 10. Clutch disc
3. Washer 11. Return clip
4. Clutch tube 12. Clutch release bearing
5. Union bolt AA" "AA 13. Release fork
6. Union 14. Release fork boot
7. Gasket 15. Fulcrum
8. Clutch release cylinder

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

21B-2-1a CLUTCH – Clutch

REMOVAL AND INSTALLATION

<F5M41-4G18, F5M42-4G94>

18 Nm

2
4
1
3

10 Nm 15 Nm

18 Nm

Removal steps
1. Clutch fluid line bracket
2. Insulator
3. Washer
4. Clutch tube
5. Clutch release concentric cylinder
assembly
6. Clutch release fork boot
7. Clutch cover
8. Clutch disc

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Added

 CLUTCH – Clutch 21B-2-2
REMOVAL AND INSTALLATION
<F5M42-4G92-MIVEC, 4G64-GDI, 6A12-MIVEC, 6A13, W5M42>

18 Nm
2
1
3

35 Nm

12 18 11
15
13 17

15 Nm 6

22 Nm
16
14 18 Nm
7
4
5
9
8
18 Nm 15 Nm
10
18 Nm

Removal steps
1. Clutch fluid line bracket 10. Clutch release cylinder
2. Insulator 11. Clutch damper
3. Washer 12. Clutch cover
4. Clutch tube (A) 13. Clutch disc
5. Tube clip 14. Return clip
6. Clutch tube 15. Clutch release bearing
7. Union bolt AA" "AA 16. Release fork
8. Union 17. Release fork boot
9. Gasket 18. Fulcrum

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

21B-2-2a CLUTCH – Clutch

REMOVAL AND INSTALLATION

<F5M42-4G93, 4G93-GDI (For SPACE RUNNER), 4G63, 4G64, 4D68>

18 Nm
2
1
3

35 Nm

9 15
12

10 14

13 22 Nm
11
5

7 6 15 Nm
18 Nm
8

18 Nm

Removal steps
1. Clutch fluid line bracket 9. Clutch cover
2. Insulator 10. Clutch disc
3. Washer 11. Return clip
4. Clutch tube 12. Clutch release bearing
5. Union bolt AA" "AA 13. Release fork
6. Union 14. Release fork boot
7. Gasket 15. Fulcrum
8. Clutch release cylinder

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

 CLUTCH – Clutch 21B-2-2b
REMOVAL AND INSTALLATION <F5M42-4G93-GDI (For CARISMA)>

35 Nm

6 12
9
7 11

10 22 Nm
8
2

4 3 15 Nm

18 Nm

5
18 Nm

Removal steps
1. Clutch tube 7. Clutch disc
2. Union bolt 8. Return clip
3. Union 9. Clutch release bearing
4. Gasket AA" "AA 10. Release fork
5. Clutch release cylinder 11. Release fork boot
6. Clutch cover 12. Fulcrum

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

21B-2-2c CLUTCH – Clutch

REMOVAL AND INSTALLATION <F5M51>

18 Nm

5
4
15
15 Nm
18 Nm 15 Nm 12
2
9.8 Nm
1 11
3 16
10
9

7 8
6
22 Nm

24
21
13
23
22
14 20

20
18 25
17
19

18 Nm

Removal steps
1. Clutch fluid line bracket 13. Clutch cover
2. Insulator 14. Clutch disc
3. Washer "DA 15. Sealing cap
4. Clutch tube (A) 16. Release fork shaft
5. Clutch tube 17. Support spring (L)
6. Union bolt 18. Packing
7. Union "CA 19. Release fork
8. Gasket "BA 20. Bushing
9. Valve 21. Clutch release bearing
10. Valve spring 22. Packing
11. Clutch release cylinder 23. Support spring (R)
12. Clutch damper 24. Release fork boot
25. Maintenance hole cover

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

 CLUTCH – Clutch 21B-2-3
REMOVAL SERVICE POINT
AA" RELEASE FORK REMOVAL
Move the release fork in the direction shown to remove the
clip from the fulcrum.

Release Fork

INSTALLATION SERVICE POINTS

"AA RELEASE FORK INSTALLATION
Apply grease Apply/pack grease to the illustrated positions of the release
fork.
Specified grease:
MITSUBISHI genuine grease part No. 0101011 or
equivalent

Pack grease

Pack grease

"BA BUSHING INSTALLATION

Press in the bushing into the release fork to the position shown
in the illustration.

Bushing TFM0710

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

21B-2-4 CLUTCH – Clutch

"CA RELEASE FORK INSTALLATION

Apply/pack grease to the illustrated positions of the release
fork.
Apply grease
Specified grease:
MITSUBISHI genuine grease Part No. 0101011 or
equivalent

Apply grease

Pack grease
TFM0919

"DA SEALING CAP INSTALLATION

2 mm Press in the sealing cap to the position shown in the illustration.
Be sure that it is not installed aslant.

TFM0712

E Mitsubishi Motors Corporation Dec. 2000 PWEE9508-H Revised

 CLUTCH - Clutch 21B-2-3
21B-2-4a
INSPECTION
CLUTCH COVER
Check the diaphragm spring end for wear and uneven height.
Replace if wear is evident or height difference exceeds the
limit. <F5M41, F5M42, W5M42>
Limit: 0.5 mm
Check the pressure plate surface for wear, cracks and
discoloration.
Check the rivets of the strap plate for looseness. If loose,
replace the clutch cover.

CLUTCH DISC
Rivet sink
Caution
Don’t clean the clutch disc in a cleaning fluid.
Check the facing for loose rivets, uneven contact, evidence
of seizure, or deposited oils and greases. If defective, replace
the clutch disc.
Measure the rivet sink and replace the clutch disc if it is out
of specification.
Limit: 0.3 mm
Check the torsion spring for looseness and damage. If
defective, replace the clutch disc.
Combine the clutch disc with the input shaft and check for
sliding condition and play in the rotating direction. If poor
sliding condition is evident, clean, reassemble, and recheck.
If excessive looseness is evident, replace the clutch disc and/or
input shaft.

CLUTCH RELEASE BEARING

Caution
Release bearing is packed with grease. Therefore, do
not wash it in a cleaning fluid and the like.
Check for seizure, damage, noise or improper rotation.
Check for wear on the surface which contacts with the
diaphragm spring. <F5M41, F5M42, W5M42>
Check for wear on the surface which contacts with release
fork. If abnormally worn, replace.

E Mitsubishi Motors Corporation Jun. 1998 PWEE9508-E Revised

21B-2-4b CLUTCH - Clutch

Check the pull ring for wear and replace the clutch release
<F5M51> bearing if necessary. <F5M51>

TFM0920

RELEASE FORK
If the surface which contacts with the bearing is abnormally
worn, replace.

RELEASE FORK SHAFT <F5M51>

Check the release fork shaft for bend and wear, and replace
if necessary.

E Mitsubishi Motors Corporation Jan. 1997 PWEE9508-C Added

 CLUTCH - Clutch Release Cylinder 21B-3-1
3. CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY <F5M41, F5M42, W5M42>

5 3

1
2
11 Nm

TFM0594

Disassembly steps
1. Cap AA" "AA 5. Piston cup
2. Air bleeder AA" "AA 6. Piston
3. Push rod 7. Conical spring
4. Boot 8. Release cylinder

E Mitsubishi Motors Corporation Nov. 1995

Jun. 1998 PWEE9508-A
PWEE9508-E Added
Revised
21B-3-2 CLUTCH - Clutch Release Cylinder

DISASSEMBLY AND REASSEMBLY <F5M51>

11 Nm

3
7
TFM0709
5
6

Disassembly steps
1. Cap AA" "AA 5. Piston cup
2. Air bleeder AA" "AA 6. Piston
3. Push rod 7. Conical spring
4. Boot 8. Release cylinder

DISASSEMBLY SERVICE POINT

AA" PISTON CUP / PISTON REMOVAL
Remove the piston from the release cylinder using compressed
air.
Caution
1. Cover with shop towel to prevent the piston from
popping out.
2. Apply compressed air slowly to prevent brake fluid
from splashing.

E Mitsubishi Motors Corporation Nov. 1995

Jan. 1997 PWEE9508-A
PWEE9508-C Added
Revised
 CLUTCH - Clutch Release Cylinder 21B-3-1
21B-3-2a
REASSEMBLY SERVICE POINT
"AA PISTON / PISTON CUP INSTALLATION
After applying brake fluid to the inside wall surface of the
release cylinder and all the circumferential surfaces of the
piston and piston cup, insert the piston and piston cup into
the cylinder.
Specified brake fluid:
Brake fluid SAE J1703 (DOT3)

INSPECTION
RELEASE CYLINDER
Check the inside wall surface of the release cylinder for rust
and damage.
Using a cylinder gauge, measure the inside diameter of the
release cylinder at about three positions (the deepest, middle
and brim positions). If the clearance from the outside diameter
of the piston exceeds the limit, replace the release cylinder
as an assembly.
Limit: 0.15 mm

E Mitsubishi Motors Corporation Nov. 1995

Jan. 1997 PWEE9508-A
PWEE9508-C Added
NOTES