TCH
OVERHAUL
CONTENTS 21209000100
CLUTCH .................................. .3 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2
Lubricants................................... 2
CLUTCH RELEASE CYLINDER ............. 7
Semice Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS ......................... .2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2
21 B-2 CLUTCH OVERHAUL - Specifications
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GENERAL SPECIFICATIONS *
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Items 1 F5M41 I F5M42
Clutch operating method ~ Hydraulic type 1 Hydraulic type
Clutch disc type ~ Single dry disc type 1 Single dry disc type
Clutch disc size O.D. x I.D. mm (in.) I 200 x 130 (7.87 x 5.12) ~ 215 x 140 (8.46 x5.51)
Clutch cover type Diaphragm spring type 1 Diaphragm spring type
Clutch cover setting load N (Ibs.) 4193 (937) 4539 (1014)
Clutch release cylinder I.D. mm (in.) 20.64 (13/16) 20.64 (13/16)
SERVICE SPECIFICATIONS 2120003OO85
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Clutch disc facing rivet sink mm (in.) 0.3 (0.012)
Diaphragm spring end height difference mm (in.) 0.5 (0.020)
Release cylinder I.D. to piston O.D. clearance mm 0.15 (0.0059)
TORQUE SPECIFICATIONS 21200180032
Items Nm ft.lbs.
Clutch tube flare nut 15 11
Clutch fluid line bracket L ?:
18 14
Clutch reiease cylinder union bolt 22 17
I Clutch release cylinder air bleeder I 11 18 - I
I Clutch release cylinder mounting bolt I l8
I Fulcrum I35
LUBRICANTS 21200040071
I Items ~ Specified lubricants
Release fork and fulcrum contact surface MlTSUBlSHl genuine grease Part
No.0101011 or equivalent
Release fork and release cylinder push rod contact surface
I Release fork and release bearing contact surface 1
I Piston and piston cup O.D. ~ Brake fluid SAE J1703 (DOT3)
I Release cylinder I.D.
&. ,.;GLUTCH 'OVERHAUL - Clutch 21 B-3
El,WTCH 21200100090
REMOVAL AND INSTALLATION
- - _ I
18Nm
14 ft.lbs.
14 ft.lbs.
TFM0595
Removal steps
1. Clutch fluid line bracket 9. Clutch cover
2. Insulator F B d 10. Clutch disc
3. Washer 11. Return clip
4. Clutch tube 12. Clutch release bearing
5. Union bolt d e F A 4 13. Release fork
6. Union 14. Release fork boot .
7. Gasket 15. Fulcrum
8. Clutch release cylinder
21 B-4 CLUTCH OVERHAUL - Clutch -*-...._-
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REMOVAL SERVICE POINT
+ A b RELEASE FORK REMOVAL
(1) Move the release fork in the direction shown to remove
the clip from the fulcrum.
I TFM0603
INSTALLATION SERVICE POINTS
b A 4 GREASE APPLICATION TO RELEASE FORK
Specified grease:
MITSUBISHI genuine grease part No.0101011 or
eq uivalent
I TFM0604
- F B I ( CLUTCH DISC INSTALLATION
, (1) Apply the specified grease to the clutch disc splines and
rub it in the splines with a brush.
I Specified grease:
MlTSUBlSHl genuine grease part No.O1O1O1l or
equivalent
(2) Using the clutch disc guide to position the clutch disc
on the flywheel.
hJ-’ Z6CLO28
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INSPECTION 21200110062
CLUTCH COVER
(1) Check the diaphragm spring end for wear and uneven
height. Replace if wear is evident or height difference
exceeds the limit.
Limit: 0.5 mm (0.020 in.)
(2) Check the pressure plate surface for wear, cracks and
discoloration.
(3) Check the rivets of the strap plate for looseness. If loose,
replace the clutch cover.
CLUTCH DISC
Rivet sink Caution
h Don’t immerse and clean the clutch disc in a cleaning
solvent.
(1) Check the facing for loose rivets, uneven contact,
evidence of seizure, or deposited oils and greases. If
defective, replace the clutch disc.
(2) Measure the rivet sink and replace the clutch disc if it
is out of specification.
Limit: 0.3 mm (0.012 in.)
(3) Check the torsion spring for looseness and damage. If
defective, replace the clutch disc.
(4) 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.
21 B-6 CLUTCH OVERHAUL - @E~lt~h -1:: ”’ . “a
CLUTCH RELEASE BEARIN n
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Caution
Release bearing is- p&&d with grease. Thercfcrre, do
not immerse and clean it in a cleaning solvent.
(1) Check for seizure, damage, noise or improper rotation.
(2) Check for wear on the surface which contacts with the
diaphragm spring.
(3) Check for wear on the surface which contacts with release
fork. If abnormally worn, replace.
RELEASE FORK
If the surface which contacts with the bearing is abnormally
worn. redace.
CLUTCH OYERHAUL - Clutch Release Cylinder * 2183-7
CLUTCH RELEASE CYL4NDER 21200150088
DISASS.EMRLY AND REAS$EMRLX
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2 1
11 Nm
8 ft.lbs.
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TFM0594
Disassembly steps
1. Cap + A b F A 4 5. Piston cup
2. Air bleeder 4 A b F A 4 6. Piston
4
3. Push rod 7. Conical spring
4. Boot 8. Release cylinder
DISASSEMBLY SERVICE POINT
+ A F PISTON CUP/PISTON REMOVAL
(1) 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.
REASSEMBLY SERVICE POINT
F A + PISTON/PISTON CUP INSTALLATION
(1) Apply brake fluid to the bore of the release cylinder, and
immerse the piston and piston cup in a brake fluid.
(2) Insert the piston and piston cup into the cylinder.
Specified brake fluid:
Brake fluid SAE .I1703 (DOTS
21 B-8 CLUTCH OVERHAUL - Clutch Release Cylinder
INSPECTION
(1) Check the bore of the release cylinder for rust, scratches
or damage.
(2) Using a cylinde , measure the inside diameter
of the release at about three positions (the
deepest, middie and h i m positions). If the clearancefrom
the outside diameter of the piston exceeds the limit,
repiace the release cylinder as an assembly.
Limit: 0.15 cram (0.0059 in.)
