CLUTCH SYSTEM

GENERAL CLUTCH MASTER CYLINDER

SPECIFICATION ........................................... CH - 2 COMPONENTS ............................................ CH - 21
DESCRIPTION .............................................. CH - 3 DISASSEMBLY ............................................. CH - 22
INSPECTION ................................................ CH - 9 REASSEMBLY .............................................. CH - 23
SPECIAL TOOL ............................................. CH - 15
CLUTCH BOOSTER
CLUTCH CONTROL SYSTEM COMPONENTS ............................................ CH - 24
COMPONENTS ............................................ CH - 16
REMOVAL ..................................................... CH - 17 DISASSEMBLY OF THE PISTON
INSTALLATION ............................................. CH - 17 ASSEMBLY ................................................... CH - 26
INSPECTION ................................................ CH - 18 REASSEMBLY .............................................. CH - 30
INSPECTION ................................................ CH - 35
CLUTCH PEDAL
COMPONENTS ............................................ CH - 19
REMOVAL ..................................................... CH - 19
INSTALLATION ............................................. CH - 19
INSPECTION ................................................ CH - 20
CH -2 CLUTCH SYSTEM

GENERAL
SPECIFICATION E1CAD1BC

Item Specification
Clutch Type Pull type
Drive type Strap drive
Clutch disc type Single dry plate
Facing(O.D X I.D) , mm 430 x 240
Pressure plate type Diaphragm
Clutch control Control type Hydraulic control with clutch booster installed
Clutch pedal 160~165(ZF6S-1900)
Stroke(mm)
,150~155(M8S5,M10S5,M12S5)
Clearance(mm) 3~5
Master cylinder Diameter(mm) Ø 24
Stroke (mm) 34
Clutch oil DOT 3, DOT 4 brake oil
Temperature range -40 ~ 80 C
Play between piston and piston rod(mm) 0.2 ~ 0.8
Booster Type Play non-adjustment type(AUTO)
Temperature range -40 ~ 100 C
Air piston I.D(mm) 100
Hydraulic cylinder I.D(mm) 25
18.5~21.5(ZF6S-1900)
Push rod operating distance(mm)
,17~20(M8S5,M10S5,M12S5)

TIGHTENING TORQUE

Tightening torque
Item
Nm kgf.m lb-ft
Clutch cover stud bolt(12ps.) 58.8 6 43.6
Master cylinder mounting bolt 28.4~58.8 2.9~6.0 21.1~43.6
Master cylinder push-in connector 19.6~29.4 2 ~ 3 14.5~21.8
M8 19.6~28.4 2~2.9 14.5~21.1
Clutch booster mounting bolt
M10 42.1~50 4.3~5.1 31.3~37.1
GENERAL CH -3

DESCRIPTION E4938C19

The clutch system consists of clutch proper and control.

The clutch proper transmits or disconnects power from
the engine to the transmission and performs the following
functions when the clutch pedal is operated.
• Transmitting engine power smoothly to the transmis-
sion as the vehicle is started.
• Temporary disconnect engine power to make trans-
mission gear shifting easy.

CLUTCH PROPER

The clutch consists of the clutch disc that transmits power

from the engine to the transmission and the clutch cover
that presses the clutch disc tight up against the flywheel.
Clutch disc is connected to the drive pinion of the trans-
mission.
The pressure plate presses the clutch disc tight up against
the flywheel to transmit power from the engine.

Diaphragm spring

Drive pinion

Flywheel
Clutch disc
Fulcrum ring
Clutch cover(Pressure plate)
SPYCH7001L

CLUTCH CONTROL

When the clutch pedal is pushed down, the clutch booster

is operated by the fluid pressure from the clutch mas-
ter cylinder. Clutch booster presses release fork, release
bearing. The release lever, operating on a force being ap-
plied with the support lever pin as the fulcrum, compresses
the pressure spring. As a result, the pressure plate is
pulled back, cutting off power from the engine.
CH -4 CLUTCH SYSTEM

CLUTCH CONTROL

5 : Cutting off power from the engine

3 9

B 8

1 10

A
1. Clutch pedal 7
2. Clutch master cylinder 6
3. Clutch reservoir tank
4. Clutch booster 4
5. Air tank
6. Push rod
7. Release fork
8. Clutch disc
9. Clutch cover
10. Flywheel

A : Water pressure
B : Air pressure

SPYCH7002L
GENERAL CH -5

CLUTCH MASTER CYLINDER

From brake fluid

0.6 Hole reservoir tank
Push rod
Nut

Master cylinder
housing

To clutch booster
control valve

Ball joint
Valve Bellow
Piston

SPYCH7003L

1. When pushing the clutch pedal down 2. When releasing the clutch pedal
As the push rod compresses the piston, piston valve The piston moves to stopper washer by the hydraulic
is closed by fluid pressure. pressure and return spring tension, the fluid pressure
is released through the 0.6 hole.

Hole(0.6mm)
Hole(0.6mm)

Push rod
Return spring

SPYCH7004L

SPYCH7005L
CH -6 CLUTCH SYSTEM

CLUTCH BOOSTER

The clutch booster is the device that eases the clutch op-
eration by using compressed air and the oil pressure gen-
erated in the master cylinder.

Air piston Visual wear indicator(VWI)

Bellow

Push rod

Valve housing & nipple

SPYCH7006L

OPERATING PRINCIPLE 2. The spool is moved more, the lower seat of air valve
is opened. The compressed air reaches to the inside
1. If the clutch pedal is pushed down, fluid pressure is of clutch booster housing. Then the air piston moves
generated in the clutch.The spool moves to the "->" di- to the "->" direction with the piston rod and operates
rection and the end of spool reaches to air valve.Then the clutch booster.
the exhaust passage, which is the reverse side of rear
clutch booster, will be closed.

Piston rod
Control fluid pressure

Spool
Air piston Exhaust pipe
Spool spring
Compressed air Air valve

SGVCH7008D

SPYCH7007L
GENERAL CH -7

3. If the clutch pedal is stopped, the fluid pressure is

stabilized and the air valve is replaced. Then the air
is not supplied and the pressure in clutch booster is
stabilized. Thus air piston and spool keeps up the
proper position till the clutch pedal moves.

SGVCH7009D

4. The hole in the spool center opens the entrance which

leads to the exhaust pipe, compressed air get out
through the entrance to the exhaust pipe which is rear
of clutch booster. Then the air piston moves to the
original position.

SPYCH7022D
CH -8 CLUTCH SYSTEM

VISUAL WEAR INDICATOR(VWI) and VWI connected to push rod moves together with them.
If checking the VWI, you know when you replace the clutch
If the clutch disc wears down gradually, diaphragm spring, disc easily.
release bearing, release fork in clutch cover and push rod
of clutch booster moves to "->" direction. The air piston

Clutch booster
Push rod

Visual wear indicator

Air piston
Release fork

Clutch booster Release bearing

Diaphragm

Clutch disc
Clutch cover

SPYCH7008L
GENERAL CH -9

INSPECTION E2C0A6BC

TO CONNECT THE PUSH-IN HOSE

NOTE
Push-in hose(A) : It is easy to assemble and disas-
semble the hose. It is used to connect an oil hose to
the clutch booster and clutch master cylinder and to
connect an oil hose hydraulic TGS(Transmission gear
shift). A

A
SPYCH7007D

It is connected to push the push-in hose to reverser con-

nector by hand.

SPYCH7006D

Push-in hose

Connector

SPYCH7009L
CH -10 CLUTCH SYSTEM

TO DISCONNECT THE PUSH-IN HOSE

1. Without disconnect tool

Disconnect the connector with a spanner Disconnect tool

Connector

SPYCH7012L

3) Push the disconnect tool in the direction of arrow

at the same with step 2.

SPYCH7010L

2. With disconnect tool : PP-6TR(3/8")

1) Pull the hose in the direction of arrow to make a

gap between the dust boot and the hose fitting
shoulder.

Dust boot
Hose fitting shoulder

SGVCH7016D

4) Pull the hose in the direction of arrow and discon-

nect the hose.

SPYCH7011L

2) Insert the disconnect tool in a gap and then push

the hose in the direction of arrow.

SGVCH7017D
GENERAL CH -11

BLEEDING OF THE CLUTCH SYSTEM 3. Bleeding should be done by two persons.

While depressing the clutch pedal several times so
If depressing clutch pedal does not allow for power trans- that clutch fluid can get pressure, loosen the air
fer, air trapped in the clutch system must be removed by bleeder screw until fluid and air bubble discharge
bleeding the clutch system. from the tube into the container. Then close and
The possible cause for air trap would be when oil pipe is tighten the bleeder screw and release the clutch
disconnected, when reservoir tank was made empty, or pedal.
related parts were replaced.
4. Repeat this procedure (3) until the stroke of push
1. Fill fluid of the clutch reservoir(A) to the "MAX" level. rod becomes 18.5~21.5 mm(ZF 6S-1900), 17~20
mm(M8S5,M10S5,M12S5). Check that the full
stroke of pedal becomes 155~165 mm(ZF 6S-1900),
CAUTION 150~155 mm(M8S5,M10S5,M12S5) and the free
1. Used brake fluid must be discarded. play of pedal becomes 3~4.8 mm. Finally, close and
2. Ensure that the fluid reservoir does not be- tighten the bleeder screw, and install the protector
come empty during bleeding. cap.
3. Wear protective goggles. Hydraulic fluid is
corrosive and can cause permanent eye dam- Tightening torque of air bleeder : 5.9~9.8
age. Nm(0.6~1 kgf.m ,4.4 ~ 7.3 lb-ft)
4. Use hydraulic fluid of the type SAE J 1703
D.O.T:3-4 Brake Fluid. 5. Check the clutch fluid in the reservoir tank. If neces-
sary, refill to the "MAX" level.
A

SPYCH7008D

2. Disconnect the air bleed cap from the clutch booster,

then install the vinyl pipe instead.
Immerse the other end of the pipe in a container of
the clutch fluid.

SPYCH7009D
CH -12 CLUTCH SYSTEM

GENERAL DIAGNOSTICS AND TESTS

Symptoms Possible cause Corrections

Vehicle judders when Oil-contaminated facing surface Clean or replace
starting
Disc facing surface bended Repair or replace
Wear of flywheel and pressure plate surface Repair or replace
Adjusting the release lever is poor. Repair(Inspect)
The release lever doesn’t work well. Apply grease and replace
The load of clutch spring is unevenness. Replace
The rust of disc hub and shaft spline Repair(Remove the rust , Apply grease)
The pilot bearing center is not fitted to the
Inspect and repair
bearing center on the transmission.
Deformation or loosening of the engine Correct(Tighten it to the specified
rear end-plate torque)
Reassembling state of the engine mounting
Repair or replace
rubber deforms and loosens.
The wear of universal joint or differential gear Repair or replace
Shifting gear is poor. Damage of the facing Replace the disc
Vibration and bending of the disc Repair or replace
Deformation or damage of the cover and
Replace the undesirable part
release lever
Shifting gear is poor because of hub and Remove the rust and apply
spline shaft rust. grease a little.
Wear of the pilot bearing Replace
Deformation of the disc because of the
Repair or replace
transmission load
Bubble in the booster and cylinder Inspect and repair
A quick start Oil-contaminated facing surface Clean or replace
Remove the rust and apply
The rust of hub and spline shaft
grease a little.
The release lever doesn’t work well. Repair or replace
The clutch reassembly alignment is bad. Repair
The clutch facing wears too much. Replace
Bubble in the booster and cylinder Inspect and repair
Clutch slip Oil-contaminated facing surface Clean or replace
The release lever doesn’t work well. Repair or replace
The clutch system is operated too much. Advice driver and replace
Deformation of the pressure plate Repair or replace
The clearance of release lever and pedal is small. Adjust the clearance.
GENERAL CH -13

Noise Insufficient play of the clutch pedal Adjust

Excessive wear of the clutch disc facing Replace
Unusual wear and/ or damage of the release bearing Replace
Insufficient grease on the sliding surface
Repair
of the bearing sleeve
Damaged pilot bushing Replace
Improperly installed clutch assembly or bearing Repair
Clutch oil is dried up. Waste of clutch oil Refill clutch oil.
Leakage of clutch oil Repair
Poor clutch pedal Indraft of air to the air line Bleed the clutch system.
The operation of booster and cylinder is bad. Repair and bleed the clutch system.
The release function of cover is bad. Replace
Hard to shift or will Excessive clutch pedal free play Adjust the pedal free play
not shift
Clutch disc out of place, runout is excessive
Inspect the clutch disc
or lining broken
Spline on the input shaft or clutch disc dirty or burned Repair as necessary
Faulty of the clutch pressure plate Replace the clutch cover
The vehicle vibrates Faulty of the diaphragm spring Replace
when operating the
clutch system. Faulty of the clutch disc Repair and replace

TROUBLESHOOTING

Symptoms Possible cause Corrections

Symptoms in Hard pedal Air pressure is too low. Check the air supply line.
normal state
Sponge(Pedal) In draft of air to the air line Check the hose,pipe and fitting.
Leakage at fitting Replace the gasket and O-ring.
The clutch
Mechanical faulty in the clutch system Replace the release lever and bearing.
pedal trembles.
The damaged sealing in the clutch
server disturbs partially server’s
The clutch
operating.
proper Mechanical faulty in the clutch system
Disassembly and clear the clutch
trembles.
system, and then replace all of rubber
products in the repair kit.
CH -14 CLUTCH SYSTEM

Problems in It is not easy to In draft of air to the air line(hose, pipe) Get rid of the air in the air line.
repair bleed air in the
Clearance is too small in the master
clutch system. Adjust the clearance of clutch system.
cylinder or pedal.
Oil leakage Disassembly and clear the clutch
Oil leakage(Inside):The other system, and then replace all of rubber
oil is mixed. products in the repair kit. Check the
hose,pipe and connector.
Oil leakage(Outside):The leakage
Check the hose,pipe and fitting.
of hose,pipe and fitting
Air leakage e damaged rubber products in
the clutch server disturbs partially
Oil leakage(Inside):The other server’s operating.
oil is mixed. Disassembly and clear the clutch
system, and then replace all of rubber
products in the repair kit.
Replace the old rubber seals to
Oil leakage(Inside):Seals worn.
the new ones.
Oil leakage(Outside):Hose,pipe,fitting Check the hose,pipe and connector.
Faulty of air valve Replace the air valve to new one.
Malfunction Faulty of the The lever arm of clutch proper is broken. Replace the broken part.
clutch release
Disassembly and clear the clutch
The first seal in master cylinder
system, and then replace all of rubber
is damaged.
products in the repair kit.
Check for the leakage of clutch
Oil level is too low.
system. Refill the brake oil.
Lever arm or release bearing is
damaged Check the movement of
lever and replace parts worn.
The pipe or hose is broken. Check the hose,pipe and fitting.
The clutch is The lever arm of clutch proper is broken. Replace the broken part.
not connected.
The disc spring of clutch proper Check the operation of clutch
is broken. slave cylinder.
Disassembly and clear the clutch
The clutch oil is contaminated. system, and then replace all of rubber
products in the repair kit.
The pipe or hose is broken. Check the hose,pipe and fitting.
Partial defect The clutch Server air valve Replace the air valve to new one.
slips.
The master cylinder doesn’t return
totally. Adjust the clearance.
Disassembly and clear the clutch
The clutch oil is contaminated. system, and then replace all of rubber
products in the repair kit.
GENERAL CH -15

Partial defect The clutch Master cylinder malfunction Replace the master cylinder.
(Continuous) is slowly
connected Check the pipe or hose fitting. Tighten
while the pedal Oil leakage : Pipe,fitting
the fitting or replace the O-ring or fitting.
is returned.
The pedal is - Replace the air valve.
hard and return - Disassembly and clear the clutch
Adjustment of air valve or server is bad.
of pedal is slow. system, and then replace all of
rubber products in the repair kit.
Check the hose,pipe and fitting.
The pipe or hose is broken.
Check the leakage of fitting.

SPECIAL TOOL EFDC0974

Special tool(Part No , Part name) Illustration Use

09411-8A000 Remove and Installation of clutch disc
Clutch alignment arbor

41.9mm

SPYCH7030D

PP-6TR(3/8") - Parker Hannifin Remove the push-in hose.

Disconnect Tool

SPYCH7025D
CH -16 CLUTCH SYSTEM

CLUTCH CONTROL SYSTEM

CLUTCH COVER AND DISC

COMPONENTS EC82CFBF

7
2

32.3( 3.3 , 24)

Tightening torque : Nm(kgf.m, lb-ft)

1. Clutch housing adapter(ZF 6S-1900 only)
2. Clutch housing
3. Clutch release bearing
4. Clutch release fork
5. Clutch disc assembly
6. Clutch cover assembly
7. Cover

SPYCH7013L
CLUTCH CONTROL SYSTEM CH -17

REMOVAL E375BE0E

1. Remove the control rod, transmission circumference

parts.

2. Remove the propeller.

3. Loosen snap ring cover and release bearing fixing

parts by inserting your hand into the hole of the lower
cover in the clutch housing.

4. Pull the release fork three times to loosen cover snap

ring.

5. Move transmission back enough horizontally and re-

move. SPYCH7010D

CAUTION 58.8 Nm(6 kgf.m, 43.6 lb-ft)

32Nm(3.3 kgf.m, 23.9 lb-ft)
Move the transmission back enough not to dam-
age the clutch.

6. Remove the clutch cover bolt. Remove bolts diagonal

direction for preventing it from bending or twisting.

7. Remove the clutch cover and disc.

CAUTION
"Y" direction
"X" direction
Since this cover is too heavy, two persons should (Clutch cover)
(Clutch housing)
work together or use lift. Sequence of tightening bolt

8. When removing the transmission assembly ,first SPYCH7014L

remove the push rod and booster.Then remove the

transmission after loosening the loop of snap ring by CAUTION
inserting your hand into the hole of the housing cover
- When assembling the cover ,tighten the bolt
assembly part.
in order.

CAUTION 2. When assembling the transmission assembly to

- Be careful not to hurt by adapter which is dis- the flywheel housing, pull the clutch release fork
assembled when removing the transmission. assembly in the arrow direction and connect the end
part(wedge form) of clutch release bearing to the
snap ring of clutch cover adapter assembly like "A"
INSTALLATION E1548A36 of the picture, after press the adapter into the clutch
housing. Tighten the transmission mounting bolt.
NOTE
- Get rid of the dust in the clutch housing and clear CAUTION
the disc. - When assembling the adapter to the flywheel
- Apply grease on a disc spline part for assembling housing,turn the red mark of adapter toward
the disc and cover after clearing the disc spline down in the vehicle and assemble the adapter.
part.
- During transport, the clutch is to be placed so that 3. Check assembling between clutch release bearing
the pressure plate lies at the top. and adapter assembly of clutch cover that you feel
the release fork hooked and the release fork is moved
Specified grease : CASMOLY L9508 when pushing the release fork in the reverse of arrow
direction.
1. Assemble the clutch cover and clutch disc to the fly-
wheel. Have to lock the snap ring of clutch cover
adapter which is in the "A" part.
CH -18 CLUTCH SYSTEM

NOTE 3. Heat, caused by incorrect use of the clutch, will often

lead to the friction surface of the pressure plate dis-
- Apply grease to the contact surface between re- torting and becoming concave.
lease bearing and release fork.
4. The concavity is not detrimental if the same clutch
Grease: CASMOLY L 9508 cover and disc are refitted. However, when renewing
discs it is advisable to check how deep this concavity
is.
4. Assemble the push rod and clutch booster assembly.
5. If, by measuring as shown in the illustration, it is found
INSPECTION E11EAA91 that dimension B is greater than 0.6 mm, there is an
increased risk of rapid disc wear in the future. If the
1. Check the diaphragm spring end for wear and uneven distortion or wear, dimension B, is greater than ap-
height. prox. 1 mm, the clutch cover should be renewed.

2. Check the pressure plate surface for wear, cracks and

color change.

3. Check the rivets for looseness and replace the clutch

cover assembly if necessary.

4. Check the clutch facing for loose rivets, uneven con-

tact, deterioration due to seizure, adhesion of oil, or
grease, and replace the clutch disc if defective.

5. Measure the thickness of the disc when free.

Rivet depth SPYCH7027D

CLUTCH RELEASE BEARING

1. Check the bearing for seizure, damage or abnormal

noise. Also check the diaphragm spring contacting
points for wear.

2. Replace the bearing if the release fork contacting

points are worn abnormally.

CAUTION
SPYCH7015L
- The release bearing is packed with grease.
Limit : rivet depth - 1.3 mm or less Do not use cleaning solvent or oil.

CLUTCH RELEASE FORK

CHECKING THE PRESSURE PLATE
1. If there is abnormal wear at the point of contact with
1. Check the friction surface of the pressure plate for
the bearing, replace the release fork assembly.
heat damage.

2. If the friction surface of the pressure plate has deep

thermal cracks or bluing that may sometimes be ob-
vious as a movement of the material, the clutch cover
should not be re-used. The method of machining
or grinding the friction surface of the pressure plate
should not be used, as this affects the clamping force.
CLUTCH CONTROL SYSTEM CH -19

CLUTCH PEDAL

COMPONENTS E39901D4

6
3

7 2

1. Master cylinder
2. Clutch switch
3. Pedal shaft 5
4. Clutch pedal arm
5. Pedal pad
6. Master cylinder reservoir tank
7. Return spring
8. Ball joint
9. Mounting bolt
9
38.2~58.8(3.9~6, 28.4~43.6)
Tightening torque : Nm(kgf.m, lb-ft)

SPYCH7054L

REMOVAL EFCD0B68 INSTALLATION E1DCFF9A

1. Drain the clutch oil before removing the clutch pedal. 1. The installation is the reverse of removal.

2. Disconnect the clutch hose from the master cylinder. NOTE

Apply grease to the spring and bush in the
3. Remove the clutch pedal mounting bolt. shaft.(LIG-2 MS511-07)

4. Remove the clutch pedal return spring. 2. Tighten the clutch pedal bracket mounting bolts and
install it.Connect the hose.
5. Remove the clutch switch. 3. Bleed the clutch system.

6. Remove the master cylinder.

7. Remove the pedal arm, shaft, ball joint pad.

CH -20 CLUTCH SYSTEM

INSPECTION E0B7CDE3 (M8S5,M10S5,M12S5 TRANSMISSION)

1. Check the clutch pedal operating distance(A) and free

play. Adjust the operating distance by a nut of stop
lamp switch and free play by nut of master cylinder
push rod. Disconnect the connector so that the wiring
of stop lamp switch may be not snarled.
The clearance(B) to be equivalent to 0.5 ~0.8 mm
between the push rod of the master cylinder and the
piston.

CLUTCH PEDAL STROKE AND CLEARANCE

SPYCH7014D

M8S5, M10S5,
Item F6S-1900
M12S5
Clutch pedal
160~165 mm 150~155mm
stroke(A)
Clutch pedal
B 3~5 mm 3~5 mm
stroke(B)
A
Booster push
SPYCH7012D
rod operating 18.5~21.5 mm 17~20 mm
distance(C)
BOOSTER PUSH ROD STROKE

(ZF6S-1900 TRANSMISSION) 2. Check that the booster push rod operating dis-
tance(C) is within standard value when pushing the
clutch pedal to the full stroke(A).If needed , bleed the
clutch system.

SPYCH7013D
CLUTCH CONTROL SYSTEM CH -21

CLUTCH MASTER CYLINDER

COMPONENTS E04F8600

1
2

5 9
10
6 11

12

3
4
7
8

1. Master housing 7. Lip seal

2. Master spring 8. Master piston
3. Valve cap 9. Washer
4. Valve 10. Retainer
5. Lubber bushing 11. Bellow
6. Tube 12. Push rod

SPYCH7016L
CH -22 CLUTCH SYSTEM

DISASSEMBLY EE889900

Cylinder housing
1. Remove the push rod and bellow from the cylinder
housing.
Spring

Cylinder housing Master cylinder piston

Washer

Bellow

Push rod

SPYCH7019L

4. Remove the tube.

SPYCH7017L Cylinder housing

2. Remove the retainer.

CAUTION
- When removing the retainer,the master cylin-
der piston may spring up.
Then remove the retainer with pushing up the
washer.
Tube

Cylinder housing
SPYCH7020L

5. Remove the rubber bushing.

Retainer

Cylinder housing

SPYCH7018L

3. Remove the washer, master cylinder piston, spring.

Rubber bushing

SPYCH7021L
CLUTCH CONTROL SYSTEM CH -23

REASSEMBLY E0072F94

Cylinder housing
NOTE
- Before reassembling clean the unit with alcohol ,
brush, towel and compressed air, then apply the Spring
specified grease to the each unit. Master
cylinder
piston
1. Apply the silicon grease to the rubber part and com-
press the rubber bushing.

Cylinder housing

SPYCH7022L

4. Install the washer with pushing the spring and install

the retainer.

Cylinder housing

Rubber bushing
Washer

SPYCH7021L Retainer

2. Assemble the tube.

Cylinder housing

SPYCH7023L

5. Install the bellow and push rod.

Cylinder housing
Tube

Bellow

SPYCH7020L

Push rod
3. Apply the silicon grease to the master cylinder piston
seal and inner part.
Compress the spring and insert master cylinder pis-
ton.

SPYCH7017L
CH -24 CLUTCH SYSTEM

CLUTCH BOOSTER

COMPONENTS E03921FA

12 37
104
39
48 47 38
18 43 44 40
11 47
9 4546 41
8 42

10
7 36 35
6
1 17
16
14 34
13 33
14 32
15
14 30
13 5 103
23 29
4
22 28
27 27
25
3
24
102
21
2 19
20
49
31 101

Consist of parts marked " "

SPYCH7053L
CLUTCH CONTROL SYSTEM CH -25

Kit No. Part name Kit No. Part name

101 Main repair kit 102 Air valve repair kit

Parts number Description Parts Number Description

2 Bellow 19 Nipple assembly
4 O-ring 20 Air filter
8 Guide ring(L=305) 21 O-ring
9 Lip seal 22 Valve housing
15 Lip seal 23 O-ring
16 Lip seal 24 Valve spring
17 Support ring 25 Valve piston
20 Air filter 31 Screw
21 O-ring
23 O-ring Kit No. Part name
24 Valve spring 103 Spool repair kit
25 Valve piston
28 O-ring Parts Number Description
29 O-ring 27 Spool
30 Lip seal 28 O-ring
31 Screw 29 O-ring
32 Bleed nipple cover 30 Lip seal
34 O-ring
35 Drain nipple cover Kit No. Part name
37 Exhaust valve cover 104 VWI repair kit
38 Valve disc
39 Exhaust rivet Parts Number Description
43 Housing
44 Disc wear indicator rod
45 O-ring
46 Washer
47 Grip ring
48 Sleeve

SPYCH7024L

Caution when disassembling

- Clear the dirt and dust from repairing parts.
- For reassembling accurately ,mark the connection
part aligned.
- Store the disassembled parts in order. Then refer to
the sequence when reassembling the parts.
- Don’t use the rubber parts again. Clear the steel parts
by cleansers which is ethylene ranges.
- Clear the rubber parts by alcohol.
CH -26 CLUTCH SYSTEM

DISASSEMBLY OF THE PISTON

ASSEMBLY E26A64E3

1 2
4

5
6
7
8
13

9
10
11
10
9
10
11
1. Push rod 12
2. Bellow
3. Cover
4. O-ring
5. Air piston
6. Support ring
7. Air piston spring
8. Lip seal
9. Retainer
10. Washer
11. Lip seal
12. Plastic bearing
13. Piston rod

SPYCH7025L

1. Lay the push rod to face the upper direction and fix
the clutch server to the vise.
Bellow
Detach the bellow and cover tap.

CAUTION
- Be care that the cover may rush out by spring Push rod
tension.

Clutch server

SPYCH7026L
CLUTCH CONTROL SYSTEM CH -27

2. Disassemble the push rod and cover.

Washer
Retainer
Cover Washer
Lip seal

Push rod

Clutch server

SPYCH7030L

SPYCH7027L 6. Pull out the plastic bearing.

3. Pull out the air piston spring and O-ring.

Plastic bearing

O-ring

Air piston spring

Clutch server

Clutch server

SPYCH7031L

SPYCH7028L

4. Extract the outside lip seal’s retainer, first washer and

outside lip seal in order.

Retainer
Washer
Lip seal

Clutch server

SPYCH7029L

5. Extract the second washer, inner lip seal’s retainer,

third washer and inner lip seal in order.
CH -28 CLUTCH SYSTEM

DISASSEMBLY OF THE AIR VALVE PACKAGE

10 11
9
8
6 7

4
3
2
1

1. Lip seal
2. O-ring
3. O-ring
4. Spool
5. Spool spring
6. O-ring
7. Valve housing
8. Air valve tap
9. Air valve spring
10. O-ring
11. Valve nipple

SPYCH7032L

1. Remove the 2 valve nipple mounting bolts and pull out

the valve housing and valve nipple.
Clutch server

Clutch server

Spool spring
Valve housing & nipple

SPYCH7034L

3. Pull out the spool.

SPYCH7033L

CAUTION
2. Extract the spool spring.
- Be care not to damage to the spool.
CLUTCH CONTROL SYSTEM CH -29

Clutch server Clutch server

Drain nipple

Spool Drain
nipple cover

SPYCH7035L SPYCH7038L

DISASSEMBLY OF THE EXHAUST VALVE DISASSEMBLY OF THE VISUAL WEAR INDICATOR

1. Strip the rubber cap. 1. Loosen the VWI(VISUAL WEAR INDICATOR) using
spanner.

Clutch server Rubber cap

SPYCH7036L
SPYCH7601D

2. Pull out the plastic splinter in the center and disas-

2. Pull out the VWI.
semble the rubber disc.

Plastic splinter

Clutch server
Rubber disc

SPYCH7602D
SPYCH7037L

DISASSEMBLY OF THE DRAIN NIPPLE

1. Detach the drain nipple cover and disassemble the

drain nipple.
CH -30 CLUTCH SYSTEM

REASSEMBLY EFF402D1

NOTE Clutch server Rubber cap

- Before reassembling clean the unit with alcohol ,
brush, towel and compressed air, then apply the
specified grease to the each unit.

REASSEMBLY OF THE DRAIN NIPPLE

Reassemble the drain nipple and the drain nipple cover.

Clutch server SPYCH7036L

REASSEMBLY OF THE AIR VALVE PACKAGE

Drain nipple
CAUTION
- Be care not to damage the rubber parts or
spool by a screw driver.
Drain
nipple cover 1. Reassemble the small O-ring.

SPYCH7038L

Lip seal
REASSEMBLY OF THE EXHAUST VALVE
O-ring
1. Reassemble the exhaust valve rubber disc and the
plastic splinter. O-ring

Spool

Plastic splinter

Clutch server
Rubber disc
SPYCH7039L

2. Reassemble the other O-ring.

3. Turn the lip toward down direction and reassemble the

lip seal in the lower parts of spool

4. Apply grease to the spool assembled with seals and

the spool spring.
SPYCH7037L
5. Turn the lip seal toward down direction and reassem-
2. Reassemble the rubber cap. ble the spool.
CLUTCH CONTROL SYSTEM CH -31

Clutch server
O-ring

Valve nipple

Spool

SPYCH7035L SPYCH7041L

6. Reassemble the spool spring. 11. Reassemble the air valve spring and reassemble the
air valve to the valve housing.
Reassemble the spool spring and spool to the clutch
server.
Clutch server

Clutch server

Spool spring Spool

Spool spring

Valve housing & nipple

SPYCH7034L

7. Reassemble the O-ring to the valve housing.

SPYCH7042L

12. Reassemble the valve housing and valve nipple and

install the 2 bolts.

O-ring Tightening torque : 7.8 Nm(0.8 kgf.m , 5.8 lb-ft)

Valve housing

SPYCH7040L

8. Reassemble the O-ring to the valve nipple.

9. Apply grease to the air valve tap, air valve spring,

seals and bushings.

10. Apply grease to the inside of valve nipple hole. SVCCH5055

CH -32 CLUTCH SYSTEM

REASSEMBLY OF THE PISTON ASSEMBLY 4. Turn the lip toward upper direction and reassemble
the outer lip seal.
1. Reassemble the plastic bearing to the server housing.

Lip seal
Plastic bearing

Clutch server
Clutch server

SPYCH7046L
SPYCH7043L
5. Reassemble the first washer and outer lip seal’s re-
2. Turn the lip toward down direction and reassemble the tainer in order.
inner lip seal.

Retainer
Washer
Lip seal

Clutch server
Clutch server

SPYCH7047L

SPYCH7044L
6. Apply grease to the inside of server housing and the
3. Reassemble the third washer , inner lip seal’s retainer seal case.
and second washer in order.
7. Reassemble the O-ring and air piston spring.

CAUTION
Washer
Retainer Turn the spring diameter on the large side toward
Washer down direction and reassemble the air piston
spring.

Clutch server

SPYCH7045L
CLUTCH CONTROL SYSTEM CH -33

O-ring

Air piston spring

Cover lip
Clutch server

SPYCH7028L SPYCH7050L

8. Reassemble the bellow to the cover and then re-

assemble it to the push rod.

Bellow

Cover

Push rod

SPYCH7048L

9. Apply grease to the air piston and piston rod.

10. Turn the lip toward inside and reassemble a lip seal to
the air piston.
Apply grease to the lip seal and reassemble it to the
cylinder housing.

Push rod
Bellow
Cover

Clutch server

SPYCH7049L

11. Reassemble the cover lip.

CH -34 CLUTCH SYSTEM

REASSEMBLY OF THE VWI(VISUAL WEAR

INDICATOR)

1. Apply LOCTITE products(or LOCTITE 572) to the

screw thread of VWI.

SPYCH7603D

2. Insert the VWI.

SPYCH7602D

3. Tighten the VWI to the specified torque.

Tightening torque : 7.8 Nm(0.8 kgf.m m 5.82 lb-ft)

SPYCH7601D
CLUTCH CONTROL SYSTEM CH -35

INSPECTION EED2D1EF

Every time installing the clutch booster and repairing or

replacing the clutch cover and disc, you must adjust the
VWI.
And then you can know when replacing the clutch disc.

1. When the clutch servo is assembled on to the vehi-

cle,or the clutch plate have been changed or serviced,
push the indicator rod inwards with a centered force
until it stops against the air piston.

Indicator rod
VWI : Visual Wear Indicator
Indicating cylinder
Air piston

SPYCH7051L

2. Then push the indicating cylinder against the indicator

housing.

Indicating cylinder

SPYCH7052L
CH -36 CLUTCH SYSTEM

INSPECTING WEAR OF A CLUTCH DISC

When the wear of the clutch disc, the air piston and the
visual wear indicator(VWI) moves as below figure. When
the dimension "C" reach the table’s specification, the new
clutch should be replaced.

"C" "C"

SGVCH7037D

SPECIFICATION

Engine D6AV D6ABDD D6CA,D6CB

Transmission M8S5 M10S5 M12S5 ZF6S-1900
"C" (mm) 27.5 27.5 24 25