21A-1
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A
CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B
21A-2
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Pedal Position Switch Adjustment . . . . . . . 4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 7
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3
Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 9
Clutch Pedal Inspection and Adjustment . . . . . . . . 3
CLUTCH - General Information/Service Specifications/Lubricants/On-vehicle Service 21A-3
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
Items Standard value
Clutch pedal height mm 202.1 - 206.1 <L.H. drive vehicles>
173.5 - 177.5 <R.H. drive vehicles>
Clutch pedal clevis pin play mm 1-3
Clutch pedal free play mm 4 - 13
Distance between the clutch pedal and the toeboard 114.3 or more <L.H. drive vehicles>
when the clutch is disengaged mm 100 or more <R.H. drive vehicles>
LUBRICANTS
Items Specified lubricants Quantity
Clutch fluid Brake fluid DOT3 or DOT4 As required
Push rod assembly Rubber grease
Boot
Release cylinder push rod MITSUBISHI genuine grease Part No.
0101011
Clutch pedal height
<L.H. drive Vehicles> <R.H. drive Vehicles>
ON-VEHICLE SERVICE
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height and the clutch pedal
A
A clevis pin play.
Standard value (A):
Clutch pedal
stopper 202.1 - 206.1 mm <L.H. drive vehicles>
173.5 - 177.5 mm <R.H. drive vehicles>
Standard value (B): 1 - 3 mm
Clutch pedal clevis pin play
B
21A-4 CLUTCH - On-Vehicle Service
3. If the height of the clutch pedal is outside the standard
Setting nut value, loosen the setting nut to adjust the pedal height
to the standard value.
Caution
Do not push in the master cylinder push rod at this
time, otherwise the clutch will not operate properly.
Clutch pedal
13 ± 2 N·m
Clutch pedal clevis pin play 4. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the clutch pedal stopper or toeboard
when the clutch is disengaged are within the standard
value ranges.
Standard value (C): 4 - 13 mm
Standard value (D):
C
114.3 mm or more <L.H. drive vehicles>
100 mm or more <R.H. drive vehicles>
5. If the clutch pedal free play and the distance between
<L.H. drive Vehicles> <R.H. drive Vehicles> the clutch pedal and the clutch pedal stopper or toeboard
when the clutch is disengaged do not agree with the
standard values, it is probably the result of either air in
the hydraulic system or a faulty master cylinder, clutch
cylinder or clutch. Bleed the air, or disassemble and inspect
D
the master cylinder, clutch cylinder or clutch.
6. Turn back the carpet, etc.
D
Clutch
pedal
stopper
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture
of the specified fluid and other fluid.
CLUTCH PEDAL POSITION SWITCH
ADJUSTMENT
1. Adjust the clutch pedal. (Refer to P. 21A-3).
2. Disconnect the connector from clutch pedal position
switch.
3. Loosen the clutch pedal position switch by rotating approx.
quarter turn to counterclockwise.
4. Fix the clutch pedal in full stroke.
CLUTCH - On-Vehicle Service/Clutch Pedal 21A-5
5. Fix the clutch pedal position switch by rotating approx.
quarter turn to clockwise in the position as shown in the
illustration.
6. Connect the connector to the clutch pedal position switch.
Full stroke 7. Check that the engine starts when the clutch is released.
position of
clutch pedal
Approx.
3.5 mm
CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
D Clutch Pedal Adjustment (Refer to P.21A-2.)
D Clutch Pedal Position Switch Adjustment (Refer to
P.21A-4.)
<L.H. drive vehicles> 13
14
12
9 10
<R.H. drive vehicles> 13 ± 2 N·m 6
5
13 8
12 ± 2 N·m 11
14
12 ± 2 N·m
1 9
7
6
12
3
2 4 8 5 11
10
13 ± 2 N·m
21A-6 CLUTCH - Clutch Pedal
Removal steps
D Column cover, under cover, lower 7. Clevis pin
frame (Refer to GROUP 52A.) 8. Clutch master cylinder mounting nut
1. Connector connection 9. Master cylinder member mounting bolt
2. Clutch pedal position switch 10. Pedal pad
3. Clutch pedal position switch sub-har- 11. Pedal stopper
ness 12. Clutch pedal assembly
4. Clip 13. Turn over spring
5. Stopper 14. Bushing
6. Snap pin
INSPECTION
CLUTCH PEDAL POSITION SWITCH CONTINUITY
CHECK
1. Connect the circuit tester (Ω range) to the connector of
No continuity Continuity clutch pedal position switch.
2. When the shaft is pushed more than the dimension as
shown in the illustration if there is not continuity, and
removing if there is continuity, the switch is good condition.
2.5 ± 1 mm
CLUTCH - Clutch Control 21A-7
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Clutch Fluid Draining D Clutch Fluid Supplying
D Clutch Pedal Adjustment (Refer to P.21A-3.)
D Clutch Pedal Position Switch Adjustment (Refer to
P.21A-4.)
D Clutch Line Bleeding (Refer to P.21A-4.)
<L.H. drive vehicles>
Release fork 15 ± 1 N·m
Release cylinder
push rod
10
11
Specified grease:
MITSUBISHI genuine grease
Part No. 0101011
4 1
12 ± 2 N·m
10 30 ± 4 N·m
18 ± 3 N·m
2
13 ± 2 N·m
3 5 7 8
6
9
11
Clutch master cylinder removal Clutch release cylinder removal
steps steps
1. Clevis pin assembly 10. Clutch pipe
2. Eye bolt 11. Clutch release cylinder
3. Gasket Clutch line removal steps
4. Reservoir hose
5. Clevis pin and pushrod assembly con- 9. Clutch hose
necting part 10. Clutch pipe
6. Clutch master cylinder
7. Sealer
8. Retainer assembly
21A-8 CLUTCH - Clutch Control
<R.H. drive vehicles>
Release fork 1
Release cylinder
push rod
13 ± 2 N·m
3
7
Specified grease:
MITSUBISHI genuine grease
5 8
4
Part No. 0101011
15 ± 1 N·m 6
18 ± 3 N·m 2
6, 8
9
7
Clutch master cylinder removal Clutch release cylinder removal
steps steps
1. Clevis pin assembly 6. Clutch pipe
2. Clutch pipe connection 7. Clutch release cylinder
3. Reservoir hose Clutch line removal steps
4. Clutch master cylinder
5. Sealer 8. Clutch pipe
9. Clutch hose
CLUTCH - Clutch Control 21A-9
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
Caution
Do not disassemble piston assembly.
6 13 ± 2 N·m
7
3
4
5
1
2
8 5
8
<L.H. drive vehicles>
<R.H. drive vehicles>
4 2
1
2
3
4
Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease
Disassembly steps
1. Piston stopper ring 5. Spring pin
2. Piston assembly 6. Reservoir tank
"AA 3. Push rod assembly 7. Seal
4. Boot 8. Master cylinder body
INSTALLATION SERVICE POINT
"AA PUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of clutch pedal easier.
104.3 ± 0.5 mm
NOTES
21B-1
CLUTCH
OVERHAUL
CONTENTS
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . 6
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . 2
21B-2 CLUTCH OVERHAUL -
General Description/Specifications/Service Specifications/
Tightening Torque/Lubricants
GENERAL DESCRIPTION
The pull-type clutch has been adopted to improve the cut-off at high rotations and reduce the clutch
pedal pressing force.
SPECIFICATIONS
Clutch disc Type Dry single-disc type
Facing dimension mm 240 × 160
Clutch cover Type Diaphragm spring, pull-type
Set load N 9,320
Clutch control method Hydraulic method
SERVICE SPECIFICATIONS
Items Limit value mm
Clutch disc facing rivet sink 0.3
Clearance between release cylinder inner diameter and 0.15
piston outer diameter
TIGHTENING TORQUE
Items Torque N•m
Clutch tube flare nut 15 ± 2
Clutch fluid line bracket mounting bolt 18 ± 3
Clutch release cylinder air breather 11 ± 1
Clutch release cylinder mounting bolt 18 ± 3
Clutch release fork shaft mounting bolt 9.8 ± 2
Clutch release cylinder union bolt 22 ± 2
LUBRICANTS
Items Specified lubricants
Release fork and release cylinder push rod contact section MITSUBISHI genuine grease Part No.0101011
or equivalent
Release fork and release fork shaft sliding section
Release fork and release bearing contact section
Piston and piston cup circumference MITSUBISHI genuine brake fluid
“DIA-QUEEN
“DIA QUEEN BRAKE FLUID SUPER 4”
Release cylinder inner circumference or equivalent
CLUTCH OVERHAUL - Clutch 21B-3
CLUTCH
REMOVAL AND INSTALLATION
18 ± 3 N•m
9.8 ± 2 N•m
2
11
1
12
18 ± 3 N•m
15 ± 2 N•m
8
7
6
5
18 ± 3 N•m 4
22 ± 2 N•m
9 19 3
18
10
16 20
16
14
17 13
15
Removal steps
1. Clutch fluid line bracket "CA 11. Sealing cap
2. Clutch tube 12. Release fork shaft
3. Union bolt 13. Support spring (L)
4. Union 14. Packing
5. Gasket "BA 15. Release fork
"EA 6. Valve plate "AA 16. Bush
"EA 7. Valve plate spring 17. Clutch release bearing
"DA 8. Clutch release cylinder 18. Packing
9. Clutch cover 19. Support spring (R)
10. Clutch disc 20. Release fork boot
21B-4 CLUTCH OVERHAUL - Clutch
REASSEMBLY SERVICE POINTS
"AA BUSH INSTALLATION
Press the bush into the position of the release valve shown
in the illustration.
Bush
"BA RELEASE FORK INSTALLATION
Apply grease on the release fork at the position shown in
the illustration.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011
or equivalent
"CA SEALING CAP INSTALLATION
Press the sealing cap into the position shown in the illustration
2 mm
while taking care so that it is not tilted.
"DA CLUTCH RELEASE CYLINDER INSTALLATION
Release fork Fill grease in the release fork to the position shown in the
illustration.
Grease
Specified grease:
MITSUBISHI genuine grease Part No.0101011
or equivalent
Valve plate spring "EA VALVE PLATE SPRING/VALVE PLATE
Release cylinder
INSTALLATION
Set the spring’s large diameter side to the valve plate side,
and install the valve plate spring and valve plate.
Valve plate
CLUTCH OVERHAUL - Clutch 21B-5
INSPECTION
CLUTCH COVER
(1) Check the pressure plate surface for wear, cracks or
discoloration.
(2) Check the strap plate rivet for looseness. If loose, replace
the clutch cover.
CLUTCH DISC
Caution
Do not wash the clutch disc with cleaning oil.
(1) Check the facing for decomposition caused by rivet
looseness, single-side contact or seizure, and check for
the presence of grease. If any fault is found, replace
the clutch disc.
(2) Measure the rivet sinking level, and replace the clutch
disc if the limit is exceeded.
Limit value: 0.3 mm
(3) Check the torsion spring for play and breakage. If faulty,
replace the clutch disc.
(4) Set the clutch disc onto the input shaft, and check the
sliding state and for play in the rotation direction. If the
sliding state is poor, wash the disc, reassemble and then
check the state again. If there is extreme play, replace
the clutch disc or input shaft or both parts.
CLUTCH RELEASE BEARING
Caution
Grease is filled in the release bearing, so do not wash with
washing oil.
(1) Check the bearing for seizure, damage, abnormal noise
or improper rotation.
(2) Check that the pull ring of the release bearing is not
worn.
(3) If the surface where the bearing contacts the release
fork is abnormally worn, replace the bearing.
RELEASE FORK AND RELEASE FORK SHAFT
(1) If the surface where the release fork contacts the bearing
is abnormally worn, replace the release fork.
(2) Check the release fork shaft for bending and wear. If
any abnormality is found, replace the release fork shaft.
21B-6 CLUTCH OVERHAUL - Clutch Release Cylinder
CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY
11 ± 1 N•m
8
3
7
5
6
Disassembly step
1. Cap "AA 5. Piston cup
2. Air breather "AA 6. Piston
3. Push rod 7. Conical spring
4. Boot 8. Release cylinder
CLUTCH OVERHAUL - Clutch Release Cylinder 21B-7
REASSEMBLY SERVICE POINT
"AA PISTON/PISTON CUP INSTALLATION
After applying brake fluid on the inner surface of the release
cylinder and circumference of the piston and piston cup, insert
the piston and piston cup into the release cylinder.
Brake fluid
Specified fluid:
Piston
MITSUBISHI genuine brake fluid “DIA-QUEEN
Piston cup BRAKE FLUID SUPER 4” or equivalent
INSEPCTION
RELEASE CYLINDER
(1) Check the inner surface of the release cylinder for rust
and damage.
(2) Using a cylinder gauge, measure the inner diameter of
the release cylinder at approx. three positions (deepest
section, middle, opening). If the clearance with the outer
diameter of the piston exceeds the limit value, replace
the release cylinder assembly.
Limit value: 0.15 mm
NOTES
