CLUTCH

1986 Isuzu Trooper II

1986 Clutch

P’UP & Trooper II

DESCRIPTION
The clutch assembly is a dry single disc type with a
diaphragm spring to engage the pressure plate. The clutch has a
mechanically-operated release system consisting of the clutch pedal,
clutch cable, return spring, release fork and prelubricated release
bearing.

REMOVAL & INSTALLATION

CLUTCH ASSEMBLY
Removal (Except 4WD)
1) Disconnect negative battery cable. Drain transmission oil.
From inside vehicle, remove gear shift lever assembly. Loosen clutch
cable adjusting nuts and remove upper starter mount nuts at left side
of engine compartment. Remove starter wiring. Raise and support
vehicle.
2) Remove drive shaft. Remove speedometer and clutch cable.
Remove starter lower bolt and starter. Disconnect exhaust pipe from
manifold. Remove exhaust pipe bracket. Remove flywheel inspection
cover and rear transmission support mount bolt. Support transmission.
Remove rear transmission support from frame.
3) On 2WD P’UP, remove 2 lower flywheel cover mount bolts.
Remove 2 bolts mounting frame bracket to rear mount. Using a jack,
slightly raise transmission. Remove 4 crossmember-to-frame bolts.
Remove 2 bolts mounting transmission extension housing. Lower engine
and transmission assembly. Support rear of engine. Disconnect
electrical leads at transmission. Remove transmission-to-engine mount
bolts and transmission.
4) Index mark pressure plate to flywheel for reassembly
reference. Install clutch assembly aligning tool. Remove retaining
bolts evenly in a crisscross pattern.

Removal (4WD)
1) Disconnect negative battery cable. Drain transmission.
Slide transmission and transfer case shift lever boots upward on
levers. Remove gear shift lever mount bolts. Remove spring from
transfer case shift lever and both levers. Remove starter mount bolts
and starter.
2) Raise and support vehicle. Disconnect exhaust pipe from
manifold. Remove exhaust hanger from transmission. Disconnect
speedometer and ground cable at transmission. Disconnect rear drive
shaft at differential. Remove 2 center bearing mount bolts.
3) Remove first and second rear drive shafts together.
Disconnect front drive shaft at both ends. Remove return spring at
clutch fork. Disconnect clutch cable from clutch fork. Pull clutch
cable forward through stiffener bracket. Remove 2 lower flywheel guard
mount bolts.
4) Remove 2 frame bracket-to-transmission rear mount bolts
and nuts. Raise engine and transmission assembly slightly. Remove 4
crossmember-to-frame bracket bolts. Remove 2 rear mount bolts from
transfer case. Support rear of engine.
5) Remove side case mount bolts and nuts. Use care not to
lose shift rod detent spring and detent ball during side case removal.
Remove side case. Disconnect electrical connectors from transmission.
Remove shift cover and gasket from top of transfer case. Remove bolts
attaching transmission to engine.

NOTE: When removing 4WD transmission, swing transmission case

90 degrees clockwise for easier removal.

6) Pull transmission straight back to clear clutch assembly.

Tilt front of transmission down and remove. Index mark pressure plate
and flywheel for reassembly reference. Loosen pressure plate attaching
bolts evenly until pressure is relieved. Support clutch assembly with
clutch aligning tool. Remove clutch assembly. See Fig. 1.

Fig. 1: Exploded View of Clutch Assembly

Courtesy of Isuzu Motor Co.

Inspection
1) Check clutch disc for burned, worn or damaged lining,
loose rivets or very loose torsional springs. Check for smooth sliding
fit of disc hub by installing on input shaft splines. Measure amount
of wear at the circumference of the clutch disc, in direction of
rotation, with dial indicator. Replace disc and/or input shaft if wear
exceeds .039" (1 mm).
2) Check clutch lining for signs of cracks, hardening due to
heat and oil or grease contamination. Check lining thickness. Minimum
lining depth is .008" (.20 mm) above rivet heads.
3) Measure clutch disc runout, at outer edge, with dial
indicator. Maximum runout is .039" (1 mm). Check friction surfaces of
flywheel and pressure plate for scoring or roughness. Smooth slight
roughness with fine emery cloth. Standard pressure plate thickness is
.51" (13 mm). If surface is deeply scored, resurface or replace
component.
4) Inspect pressure plate for cracks and distortion. Inspect
diaphragm spring for heat distortion and loosened rivets. Check wire
ring for wear.
5) Inspect release lever ball socket, release bearing contact
face and ball retaining spring for damage. Spring must hold release
lever tightly to ball stud.

Installation (2WD & 4WD)

1) Using aligning tool, install clutch assembly in original
position. Tighten bolts evenly, in criss-cross pattern. Lightly
lubricate input shaft splines, clutch hub and release bearing contact
surfaces with molybdenum grease.
2) To complete installation, reverse removal procedure.
Readjust clutch pedal height and free play. Refill transmission.

RELEASE BEARING
Removal
Remove clutch assembly. remove release fork cover from
transmission case. Remove release bearing-to-fork retaining spring.
Remove release bearing with shift collar. Remove release fork from
transmission ball stud.

NOTE: The release bearing is permanently lubricated. Do not wash

in solvent. Clean only with compressed air and shop towel.

Inspection
Check contact areas of release bearing and release fork for
excessive wear. Check release bearing and shift collar for noise or
roughness by rotating by hand in thrust direction. Remove release
bearing (if necessary). Inspect return spring and release bearing
spring for wear.

Installation
Lubricate ball stud and install release fork. Lubricate shift
collar and install release bearing and shift collar to release fork
with retaining springs. Install clutch assembly.

PILOT BEARING
NOTE: Do not remove the pilot bearing unless absolutely necessary.
The release bearing is permanently lubricated. Do not wash
in solvent. Clean only with compressed air and shop towel.

Removal
Remove clutch assembly. Check pilot bearing for seizing,
sticking, abnormal noise or wear. Remove pilot bearing from
crankshaft.

Installation
Install pilot bearing in crankshaft bore. Bearing must be
fitted against bottom face of bearing fitting hole. Install clutch
assembly by reversing removal procedure.
 CLUTCH CABLE
Removal
1) Loosen clutch cable lock and adjusting nuts. Remove cable
clip in engine compartment. Raise vehicle. Remove return spring from
release lever. Remove clutch cable from release lever and slide it
through retaining bracket. Disconnect cable from clutch pedal and
remove.
2) Disconnect cable from hooked portion of clutch pedal and
pull out toward engine compartment together with damper rubber. Use
care not to damage rubber damper during removal. On all models, check
cable assembly and/or damper rubber for fatigue or damage. Replace as
necessary.

Installation
Slide cable through firewall and install clutch pedal.
Install cable in original position through retaining bracket to
release lever. Install clutch return spring. Adjust clutch cable and
tighten lock nut.

ADJUSTMENTS

CLUTCH CABLE FREE PLAY

Pull outer cable into engine compartment. Rotate adjuster nut
until washer damper rubber is brought into contact with firewall. Work
pedal several times. Pull outer cable out again. Fully tighten
adjusting nut. Back adjusting nut off until there is .2" (5 mm)
between adjusting nut and washer damper rubber. Release outer cable.
Tighten lock nut. See Fig. 2.

Fig. 2: Adjusting Clutch Cable Free Play

Courtesy of Isuzu Motor Co.

CLUTCH PEDAL HEIGHT & FREE PLAY

 Adjust clutch switch setting so pedal height, from floor, is
6.9-7.2" (174-184 mm) for P’UP. For Trooper II, when adjusting clutch,
pedal height should be 9.1-9.5" (231-241 mm). Insure clutch pedal free
play is .8" (20 mm).

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE


























































Application Ft. Lbs. (N.m)

Flywheel-to-Crankshaft Bolts ............. 40-70 (54-64)

Pressure Plate-to-Flywheel Bolts ......... 12-14 (16-19)
Release Lever Ball Stud ........................ 29 (39)