Installation Page 1 of 7
Clutch Booster Installation
1. Component Views
Clutch booster
Part name
1. Return spring
2. Pipe
3. Pin
4. Cotter pin and washer
5. Clutch booster
2. Clutch Booster Installation
1) Install the clutch booster to the transmission case.
2) Install the joint pin to the push rod and the clutch lever.
Note:
Apply multi-purpose type grease, chassis grease, or equivalent to the joint pin.
3) Install the return spring to the clutch booster.
4) Install clutch piping to the clutch booster.
5) Install the air piping to the clutch booster.
3. Clutch Fluid Air Bleed
If air enters the clutch circuit, it will cause clutch dragging.
Therefore, bleeding operation should be performed if the clutch has been used with the level of the clutch fluid in the reservoir
excessively lowered or if the clutch pipe has been disconnected in the course of clutch servicing.
Bleeding operation calls for cooperative action of two men.
Copyright ISUZU MOTORS LIMITED. All rights reserved.
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Installation Page 2 of 7
1) Set the parking brake.
2) Replenish the fluid tank with the clutch fluid.
Caution:
Take care that no dust or moisture enters the tank when refilling with clean clutch fluid, as it could prevent the
clutch from operating properly.
Take care not to spill the clutch fluid when refilling. If spilling does occur, wipe up immediately.
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Installation Page 3 of 7
Caution:
Because clutch fluid will decrease during the air bleeding process, take care to prevent the tank from becoming
empty.
Note:
Install the vinyl pipe to the clutch booster air bleeder.
Insert the other end into a clear container filled approximately 1/3 with brake fluid.
3) Purge air from the clutch booster.
Note:
Loosen the air bleeder and depress the clutch pedal repeatedly.
Tighten the air bleeder at the point where the pedal feels heavy.
Stop the engine and perform under conditions where the booster is not operating.
After repeatedly depressing the clutch pedal, loosen the air bleeder half a turn with the pedal pressed down, and
discharge the air.
Tighten the air bleeder before releasing the pedal.
Repeat the above-mentioned operation until the clutch fluid emitted from the air bleeder is free of air bubbles.
Take care to ensure that the clutch fluid does not become insufficient during work.
4. Clutch Pedal Inspection
1. Inspection of clutch pedal play amount
1) Lightly press the clutch pedal by hand, and inspect the pedal stroke until resistance can be felt.
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Installation Page 4 of 7
Standard： 25 to 40 mm { 0.98 to 1.57 in }
1. Clutch pedal play
2) Check that the parking brake operates properly.
3) Fully depress the clutch pedal while the engine is idling.
4) After placing the change lever in 1st gear, slowly release the clutch pedal.
5) Measure the distance from the position where the clutch pedal is fully depressed to the position immediately before
the clutch engages.
Standard： 60 mm or more { 2.36 in or more }
1. Pedal position just before clutch engagement
2. Pedal stroke
3. Position of fully pressed pedal
2. Adjustment of the clutch pedal play amount
If the amount of pedal play exceeds the specified value, adjust the master cylinder section with the engine stopped.
1) Loosen the push rod lock nut.
2) Turn until the push rod contacts the piston.
Note:
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Installation Page 5 of 7
Return 1/2 - 3/4 turns from this position.
At this time the clearance between the push rod end and piston will become the following value.
Standard： 0.5 to 1.0 mm { 0.020 to 0.039 in }
1. Clearance
3) Tighten the lock nut.
3. Pedal stroke inspection
1) After adjusting the master cylinder push rod, confirm that the pedal stroke is within the specified range.
Standard： 180 mm { 7.09 in }
1. Pedal stroke
Note:
As models with MJX transmissions are equipped with an auto adjusting clutch booster, clutch pedal play
does not change even when the clutch disc is worn.
Caution:
Replace the clutch disc when the Clutch Wear warning light illuminates.
5. Clutch Booster Adjustment
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Installation Page 6 of 7
1. Push rod
2. Link rod
3. GND
4. Signal
5. +5V
6. Return spring
7. Clutch sensor
1) Connect a scan tool to the DLC.
2) Turn ON the ignition switch.
3) Turn ON the smoother emergency switch.
4) Check the data display of a scan tool.
Note:
With the push rod pulled out until it comes in full contact, check the clutch stroke sensor voltage display.
Caution:
Secure the clutch shaft.
Standard： 0.65 to 0.85 V
5) Adjust the link rod.
Note:
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Installation Page 7 of 7
If outside the specified range, adjust the link rod length.
Caution:
After adjusting the link rod, apply Loctite to the lock nut to secure.
6) Adjust the push rod.
Note:
Return the push rod 3 1/4 rotations, and tighten the lock nut.
Tightening torque： 46 N・m { 4.7 kgf・m / 34 lb・ft }
Note:
Confirm the clutch sensor learning after adjusting.
Caution:
If the sensor link rod was removed, install as shown in the diagram.
A system malfunction will occur if correct sensing of the disengagement position becomes impossible due to
mistakes made during the setting process.
22.01.2020
