SECTION 7A - CLUTCH
MAIN DATA AND SPECIFICATIONS
GENERAL DESCRIPTION
TORQUE SPECIFICATION
SERVICING
CLUTCH
REMOVAL AND INSTALLATION
INSPECTION AND REPAIR
CLUTCH CONTROL
REMOVAL AND INSTALLATION
MASTER CYLINDER
SLAVE CYLINDER (EXCEPT 6VD1 ENGINE)
DISASSEMBLY
INSPECTION AND REPAIR
REASSEMBLY
SLAVE CYLINDER (6VD1 ENGINE)
DISASSEMBLY
INSPECTION AND REPAIR
REASSEMBLY
HYDRAULIC DAMPER CYLINDER (EXCEP T 6VD1 ENGINE)
INSPECTION AND REPAIR
TROUBLESHOOTING
SPECIAL SERVICE TOOL
MAIN DATA AND SPECIFICATIONS
ENGINE C22NE 4JB1T 6VD1
Type Dry single plate with diaphragm
Size mm(in) 240 (9.449) 260 (10.24)
Clamping force kg(lb) 560 (1235) 735 (1621)
(N) (5492) (7208)
Pressure plate
Outside diameter mm(in) 240 (9.449) 260 (10.24)
Inside diameter mm(in) 160 (6.299) 170 (6.70)
Driven plate
Thickness mm(in)
at free 8.6 (0.339) 8.3 (0.327) 8.2 (0.323)
at compressed 8.0 (0.315) 8.0 (0.315) 8.0 (0.315)
CLUTCH CONTROL
Type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Pedal height mm(in) 216-226 (8.50-8.90)
Master cylinder
Bore×Stroke mm(in) 15.87×35 (0.625×1.38)
Slave cylinder
Bore×Stroke mm(in)
C22NE / 4JB1T 22.22x15 (0.875x0.59)
6VD1 22.22×17 (0.875×0.67)
GENERAL DESCRIPTI O N
HYDRAULIC CO NTROL TYPE
HEC Engine Series 4J Engine S eries
6VD1
The clutch assembly consists of the pressure plate, the clutch cover, the diaphragm spring pivot pin and the driven
plate assembly.
The clutch pedal is connected to the shift block through the clutch shaft and the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
Diaphragm spring pressure holds the driven plate against flywheel and the pressure plate to provide the friction
necessary to engage the clutch.
Depressing the clutch pedal moves the shift fork against the shift block.
The shift block forces the release bearing against the diaphragm to overcome the force of the diaphragm spring and
separate the driven plate from the flywheel and pressure plate to disengage the clutch.
Except 6VD1 (3.2L) engine model, the conventional push-type clutch is used.
For 6VD1 (3.2L) engine model, the pull-type clutch is employed. The pull-type clutch is disengaged by pulling the
release lever (release bearing) to disengage the pressure plate.
MASTER CYLINDER
6VD1
The master cylinder converts mechanical energy into hydraulic energy.
Depressing the clutch pedal causes the push rod to move against the piston to close the return port.
Clutch fluid is forced out of the master cylinder.
Releasing the clutch pedal causes the return spring to force the piston back to its original position.
The return port is opened and the clutch fluid flows back into the fluid reservoir.
Quickly releasing the clutch pedal will cause the fluid pressure at the return spring side to be lower than the fluid
pressure at the push rod side.
This allows the fluid at the push rod side to quickly flow to the return spring side through a port in the piston head.
This equalises the pressure at both sides of the piston.
SLAVE CYLINDER
MUA Series
MSG Series
4J Engine S eries
6VD1 Engine Series
The slave cylinder converts hydraulic energy into mechanical energy.
Hydraulic fluid supplied by the master cylinder moves the slave cylinder piston to actuate the shift fork.
The mechanical energy produced by the slave cylinder is directly proportional to the diameters of the master cylinder
and the slave cylinder.
A bleeder screw is provided to bleed the slave cylinder.
HYDRAULIC DAMPER CYLINDER
The hydraulic damper cylinder is installed between the master cylinder and the slave cylinder to smooth out variations in
clutch pedal feel.
PRESSURE PLATE ASSEMBLY
HEC Engine Series 4J Engine S eries
6VD1 Engine Series
The pressure plate assembly consists of the clutch cover, the pressure plate with diaphragm spring.
Operating the clutch pedal causes the pressure plate to move in an axial direction to engage and disengage the clutch.
DRIVEN PLATE ASSEM BLY
The driven plate assembly consists of the plate and the facing.
The plate consists of the clutch centre, the cushioning plate and the torsion springs.
The facing is riveted to both sides of the cushioning plate.
The cushioning plate provides a longer service life by minimising wear and vibration at the clutch contact surfaces.
TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified.
N⋅m (kgf⋅m/lb⋅ft)
Strength 4.8/4T 7T 8.8 9.8/9T
Class Refined Non-Refined
Bolt Identifi-
cation
Bolt
Diameter×
××
×
Pitch (mm) -
M6 × 1. 0 6 (0.6 / 52 lb. i n) 7 (0.7 / 61 lb. i n) 8 (0.8 / 69 lb. i n) -
M8 × 1. 25 13 (1.3 / 113
lb.in) 17 (1.7 / 12) 20 (2.0 / 14) 24 (2.4 / 17)
M10 × 1.25 27 (2.8 / 20) 37 (3.8 / 27) 42 (4.3 / 31) 50 (5.1 / 37)
M12 × 1.25 61 (6.3 / 45) 76 (7.8 / 56) 87 (8.9 / 64) 95 (9.7 / 70)
M14 ×1.5 96 (9.8 / 71) 116 (11.8 / 85) 133 (13.6 / 98) 142 (14.5 / 105)
M16 × 1.5 130 (13.3 / 96) 170 (17.3 / 125) 193 (19.7 / 143) 200 (20.4 / 148)
M18 × 1.5 188 (19.2 / 139) 244 (24.9 / 180) 278 (28.3 / 205) 287 (29.3 / 212)
M20 × 1.5 258 (26.3 / 190) 337 (34.4 / 249) 385 (39.3 / 284) 396 (40.4 / 292)
M22 × 1.5 332 (33.9 / 245) 453 (46.3 / 335) 517 (52.7 / 381) 530 (54.1 / 391)
M24 × 2.0 449 (45.8 / 331) 570 (58.2 / 421) 651 (66.3 / 480) 692 (70.6 / 511)
*M10 × 1.5 26 (2.7 / 20) 36 (3.7 / 27) 41 (4.2 / 30) 48 (4.9 / 35)
*M12 × 1.75 57 (5.8 / 42) 71 (7.2 / 52) 80 (8.2 / 59) 89 (9.1 / 66)
*M14 × 2.0 89 (9.1 / 66) 110 (11.2 / 81) 125 (12.7 / 92) 133 (13.6 / 98)
*M16 × 2.0 124 (12.7 / 92) 162 (16.5 / 119) 185 (18.9 / 137) 191 (19.5 / 141)
Flange Bolt M6 × 1. 0 7 (0.7 / 61 lb. i n) 8 (0.8 / 69 lb. i n) 9 (0.9 / 78 lb. i n) -
M8 × 1. 25 15 (1. 5 / 11) 19 (1.9 / 14) 22 (2.2 / 16) 26 (2. 7 / 20)
M10 × 1.25 31 (3.2 / 23) 41 (4.2 / 30) 47 (4.8 / 35) 56 (5.7 / 41)
M12 × 1.25 69 (7.0 / 51) 85 (8.7 / 63) 97 (9.9 / 72) 106 (10.8 / 78)
M14 × 1.5 104 (10.6 / 77) 126 (12.8 / 93) 144 (14.6 / 106) 154 (15.7 / 114)
M16 × 1.5 145 (14.8 / 127) 188 (19.2 / 139) 214 (21.8 / 158) 221 (22.5 / 163)
M18 × 1.5 - - - -
M20 × 1.5 - - - -
M22 × 1.5 - - - -
M24 × 2.0 - - - -
*M10 × 1.5 30 (3.1 / 22) 40 (4.1 / 30) 46 (4.7 / 34) 54 (5.5 / 40)
*M12 × 1.75 64 (6.5 / 47) 78 (8.0 / 58) 89 (9.1 / 66) 99 (10.1 / 73)
*M14 × 2.0 97 (9.9 / 72) 119 (12.1 / 88) 135 (13.8 / 99.7) 144 (14.7 / 107)
*M16 × 2.0 137 (14.0 / 101) 178 (18.2 / 132) 203 (20.7 / 132) 210 (21.5 / 155)
The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as
casting, etc.
Standard Hex.
Head Bolt
FLARE NUTS
Pipe diameter mm (in) Torque N⋅
⋅⋅⋅m (kgf⋅
⋅⋅⋅m / lb⋅
⋅⋅⋅ft) Pipe diameter mm (in) Torque N⋅
⋅⋅⋅m (kgf⋅
⋅⋅⋅m / lb⋅
⋅⋅⋅ft)
4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)
6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)
8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)
SPECIAL PARTS FI XING NUTS AND BOLTS
N⋅m (kgf⋅m/lb⋅ft)
17.6±4.9 (1.8±0.5/13.0±3.6)
N⋅m (kgf⋅m/lb⋅ft)
HEC Engine Series RHD Model, 4J Engine Series
19.6±3.9
(2.0±0.4/14.5±2.9)
7.85±0.95
(0.8±0.1/5.8±0.7)
11.8±2.9
(1.2±0.3/8.8±2.2)
15.7±2.9
(1.6±0.3/11.6±2.2)
N⋅m (kgf⋅m/lb⋅ft)
6VD1 RHD Model
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
CLUTCH PEDAL HEIGHT
INSPECTION
Measure to verify that the distance from the upper surface of
the pedal pad to the firewall is within the standard value.
Clutch Pedal Height(H) mm(in)
HEC ENGINE 216-226
(8.50-8.89)
4JG2T ENGINE −
OTHER ENGINE 203-213
(7.99-8.39)
ADJUSTMENT
1. Loosen clutch master cylinder push rod lock nut 2.
Turn push rod 1 by hand to set clutch pedal height (H) to
within specification.
2. After the adjustment, tighten lock nut 2.
3. Turn the stopper bolt 3 until the stopper bolt 3 just touc hes
the clutch pedal arm.
Adjust or stopper bolt 3 by backing it out half a turn, and
measure the clearance (L) between the clutch pedal arm
and the stopper bolt 3.
Lock the lock nut 4.
Stopper Bolt and clutch pedal
Clearance mm(in)
(L) 0.5-1.5 (0.020-0.059)
CLUTCH PEDAL PLAY
INSPECTION
Depress the clutch pedal lightly by hand, and measure to
determine if the free play is wi thin the standard value.
Pedal Free Play mm(in)
H1 5.0-15.0 (0.2-0.6)
BLEEDING PROCEDURE
1. Bleed air from clutch operating cylinder according to the
following procedure.
Carefully monitor fluid level at master cylinder during
bleeding operation.
Techline
1. Set the paking brake.
2. Top up reservoir with recommended brake fluid.
3. Connect a transparent vinyl tube to air bleeder valve.
4. Fully depress clutch pedal several times.
5. W ith c lutch pedal depressed, open bleeder valve to r elease
air.
6. Close bleeder valve.
7. Repeat steps 5 through 6 above until brak e fluid flows fr om
air bleeder valve without air bubbles.
8. Bleed air from clutch damper according to the above
procedure.
9. Repeat the above bleeding procedure 1 and 2 several
times.
CLUTCH
REMOVAL AND INSTALLATION
HEC Engine S e r ies
4J E ngine Ser ies
6VD1
REMOVAL STEPS
1. Transmission assembly
▲2. Pressure Plate assembly
▲3. Driven plate assembly
4. Release bearing
5. Shift fork
6. Fly wheel assembly and crank bearing
(HEC Engine Series)
7. Fulcrum bridge (6VD1)
INSTALLATION STEPS
To install, follow the removal steps in the
reverse order.
IMPO RTANT OPERATIONS - REMOVAL
1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of Section 7B and
Section 7B1 for “REMOVAL AND INSTALLATION” procedure.
2. Clutch Pressure Plate Assembly (HEC Engine Series)
3. Driven Plate Assembly (HEC Engine Series)
(1)Use the clutch pilot aligner 1 to prevent the driven plate
assembly 2 from falling free.
Clutch Pilot Aligner : 5-8840-2634-0
(2)Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3)Remove the pressure plate assembly 3 from the flywheel.
(4)Remove the driven plate from the flywheel.
3. Driven Plate Assembly (Except HEC Engine Series)
(1)Use the pilot aligner to prevent the driven plate assembly
from falling free.
Pilot aligner: 5-8525-3001-0 (J-24547)
(2)Mark the flywheel, clutch cover and pressure plate lug fo
r
alignment when installing.
6VD1 4. Release Bearing (6VD1)
Remove the release bearing from the transmission case.
6VD1 5. Shift Fork (6VD1)
(1)Remove the snap pin.
(2)Remove the shift fork pin and shift fork from the fulcrum
bridge.
6VD1 7. Fulcrum Bridge (6VD1)
(1)Remove the fulcrum bridge bolts.
(2)Remove the fulcrum bridge from the transmission case.
IMPORTANT OPERATIONS - INSTALLATION
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.
3. Driven plate Assembly (HEC Engine Series)
2. Clutch Pressure Plate Assembly (HEC Engine Series)
(1)Clean the flywheel surface.
(2)Clean the facing surface.
(3)Use the clutch pilot aligner 1 to install the driven plate
assembly 2 to the flywheel 3.
Clutch Pilot Aligner : 5-8840-2634-0
(4)Clean the pressure plate surfaces.
(5)Align the pressure plate assembly 4 with the flywheel
knock pin 5.
(6)Install the pressure plate assembly to the flywheel.
(7)Tighten the clutch cover bolts a little at a time in the
numerical order shown in the illustration.
Clutch Cover Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
17.6 ± 4.9 (1.8 ± 0.5/13.0 ± 3.6)
8. Remove the clutch pilot aligner.
Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.
6VD1 7. Fulcrum Bridge (6VD1)
(1)Install the fulcrum bridge to the transmission case.
(2)Tighten three fulcrum bridge bolts to the specified torque.
Fulcrum Bridge Bolt Torque N⋅m (kg⋅m/lb⋅ft)
39 (3.9/28)
6VD1 5. Shift Fork (6VD1)
(1)Apply molybdenum disulfide contained type grease to the
pin hole inner circumferences and thrust surfaces.
(2)Attach the shift fork to the fulcrum bridge and insert the pin
from below of the fulcrum bridge.
(3)Install the washer and snap pin.
6VD1 4. Release Bearing (6VD1)
(1)Apply molybdenum disulfide contained type grease to the
areas shown in illustration.
6VD1 (2)Install the release bearing in the proper direction.
3. Driven Plate Assembly (Except HEC Engine Series)
Use the pilot aligner to install the driven plate assembly.
Pilot aligner: 5-8525-3001-0 (J-24547)
6VD1 2. Pressure Plate Assembly (6VD1)
(1)Tighten the bolts holding the press ure plate ass em bly in the
order shown in illustration.
Pressure Plate Bolt Torque N⋅m (kgf⋅m/lb⋅ft)
20.6±2.9 (2.1±0.3/15.2±2.2)
(2)Remove the aligner.
NOTE:
Do not strike the aligner with a hammer to remove it.
1. Transmission Assembly
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
PRESSURE PLATE ASSEMBLY
Visually inspect the pressure plate friction surface for
excessive wear and heat cracks.
If excessive wear or deep heat cracks are present, the
pressure plate must be replaced.
PRESSURE PLATE WARPAGE
Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the
pressure plate must be replaced.
Pressure Plate Warpage mm(in)
Limit
0.3 (0.012)
CLUTCH COVER
Visually inspect the entire clutch cover for excessive wear,
cracking, and other damage.
The clutch cover must be replaced if any of these conditions
are present.
1. Abrasion, sc ratc hes , c rac ks and def lec tion of f r ic tion f ac e to
the disc, loose rivet and wear of ring
•Grind small scratches, or replace the assembly if extreme
scratches are found.
CLUTCH SET FORCE (EXCEPT 6VD1)
1. Position the pressure plate assembly 1 as shown in the
illustration.
2. Place the new driven plate 2 over the pressure plate
assembly.
Driven Plate Thickness (Reference) mm(in
)
Standard
Free Compressed
HEC (MSG) 8.4 (0.330) 8.0 (0.315)
HEC (MUA) 8.6 (0.338) 8.0 (0.315)
4JG2T 8.2 (0.323) 8.0 (0.315)
4JA1 8.0 (0.315) 7.8 (0.307)
4JB1T 8.0 (0.315) 7.8 (0.307)
3. Place a metal sheet 3 between the press and the driving
plate.
4. Compress the metal sheet and the driven plate until the
driven plate is flush with the drive plate assembly A.
5. Note the pressure gauge reading.
Driven Plate Clamping Force N (kg/Ib)
Standard
HEC (MSG), 4JA1 4,903 (500/1,103)
HEC (MUA), 4JB1T 5,492 (560/1,235)
4JG2T 6,276 (640/1,411)
CLUTCH SET FORCE (6VD1)
1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate.
A metal sheet with A thickness of 8.0 mm (0.315 in) may
be used in place of the driven plate.
3. Comp ress the press ure plate ass em bly until the distance B
becomes 12 mm (0.472 in).
4. Note the pressure gauge reading.
If the measured value is less than the specified limit, the
pressure plate assembly must be replaced.
Clutch Set Force N (kg/Ib)
Standard Limit
6VD1 7,208 (735/1,621) 6,669 (680/1,499)
DIAPHRAGM SPRING FINGER HEI G HT
(EXCEPT 6VD1)
1. Place the appropriate spacer beneath the pressure plate.
Refer to the table below.
Spacer Thickness mm(in)
HEC, 4JG2T 8.0 (0.315)
4JA1, 4JB1T 7.8 (0.307)
2. Fully compress the pressure plate and the diaphragm
spring.
There are two ways to do this.
1) Use a bench pres s to pres s down the ass embly from the
top.
2) Tighten the fixing bolts.
3. Measure the spring finger height A from the base to the
spring tip.
Spring Finger Height mm(in
)
HEC MSG 37-39
HEC MUA 39.9-41.9
4JA1 30.5-32.5 (1.20-1.28)
4JB1T 35.0-37.0 (1.38-1.46)
4JG2T 39.0-41.0 (1.53-1.61)
6VD1 DIAPHRAGM SPRING FINGER HEIGHT (6VD1)
1. Place a new driven plate or an 8.0 mm (0.315 in) space
r
beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm spring.
There are two ways to do this.
1) Use a bench pres s to press down on the ass embly from
the top.
2) Tighten the fixing bolts.
NOTE: (6VD1)
Pre-load on diaphragm spring finger must be 49 - 98N (5.0
- 10.0 kg / 11 - 22 lb) in direction of release, when clutch
cover assembly is bolted to the flywheel.
3. Measure the spring height from base to spring tip A.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Spring Finger Height mm(in
)
Standard
6VD1 49.9-51.9 (1.965-2.043)
RELEASE BEARI NG REPLACEMENT
REMOVAL (EXCEPT 6VD1)
Use the bearing puller and the adapter to remove the release
bearing.
Bearing Puller : 5-8840-0013-0 (J-22888)
Adapter : 5-8840-0124-0 (J-2241-11)
RELEASE BEARING INSTALLATION (EXCEPT 6VD1)
1. Set the release bearing to the shift block bearing fitting
surfaces.
The release bearing must be perfectly horizontal.
2. Use a bench press to fit the release bearing to the shift
block.
Install the parts as illustrated after applying wheel bearing
grease or multi-purpose type grease (NLGI No.2 or No.3).
6VD1 RELE\ASE BEARING (6VD1)
1. Visually chec k the release bear ing for exc essive play, noise
and breakage.
If any of these conditions are discovered, the release
bearing must be replaced.
6VD1 NOTE:
When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.
WEDGE COLLAR (6VD1)
1. Visually check the surfaces of the wedge collar making
contact with the release bearing for excessive wear and
damage.
2. Replace any exhibiting excessive wear damage.
SHIFT FORK (EXCEPT 6VD1)
1. Visually inspect the surfaces of the shift fork making contact
with the shift block for excessive wear and damage.
2. Remove any minor s tepping or abr asion f r om the shift block
with an oil stone.
Replace any exhibiting excessive wear or damage.
3. Apply multi-purpose type grease (NLGI No.2 or No.3) to
area.
6VD1 SHIFT FORK (6VD1)
1. Visually check the surfaces of the shift fork m aking contact
with the release bearing for excessive wear and damage.
2. Remove any m inor stepping or abrasion fr om shif t fork with
an oil stone.
Replace any exhibiting excessive wear of damage.
DRIVEN PLATE ASSEM BLY
1. Visually inspect the torsion spring 1 for looseness,
breakage, and weakening.
If any of these conditions are discovered, the driven plate
assembly must be replaced.
2. Visually inspect the facing surfaces 2 for cracking and
excessive scorchi ng.
Visually inspect the facing surfaces for the presence of oil
or grease.
If any of these conditions are discovered, the facing must
be cleaned or replaced.
3. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed
with an oil stone.
DRIVEN PLATE WARPAGE
1. Insert the clutch pilot aligner into the driven plate splined
hub.
The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner : 5-8840-2634-0 (HEC Engine Series)
5-8525-3001-0 (J-24547) (Except HEC Engine Series)
2. Set a dial indicator to the driven plate outside
circumference.
3. Slowly turn the driven plate.
Read the dial indicator as you turn the driven plate.
If the measured value exceeds the specified limit, the driven
plate assembly and/or the facing must be replaced.
Driven Plate Warpage mm(in)
Standard Limit
0.7 (0.028) 1.0 (0.039)
DRIVEN PLATE SPLINED HUB SPLI NE W EAR
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft
spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven
plate.
If the measured value exceeds the specified limit, the driven
plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear mm(in)
Standard Limit
0.5 (0.020) 1.0 (0.039)
RIVET HEAD DEPRESSIO N
Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression 1 from the facing surface
2.
Be sure to measure the rivet head depression on both sides of
the driven plate.
If the measured value is less than the specified limit, the facing
must be replaced.
Rivet Head Depression mm(in)
Standard
Fly wheel side P/P l ate side
HEC 1.65∼2.25
(0.065-0.089)
4JA1 1.35∼1.95
(0.053-0.077) 1.65∼2.25
(0.065-0.089) 0.2
(0.008)
4JB1T, 4J G2T 1. 3∼1.9
(0.051-0.075)
6VD1 1.6 (0.063)
Limit
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Except 6VD1 Engine
REMOVAL STEPS
1. Pin
2. Jaw joint pin
3. Pedal assembly
4. Oil line
5. Master cylinder assembly
6. Oil line
7. Slave cylinder assembly
8. Damper cylinder assembly
INSTALLATION STEPS
To install, follow the removal steps in the
reverse order.
SLAVE CYLINDER (EXCEPT 6VD1 ENGINE)
DISASSEM BLY
DISASSEM BLY STEPS
▲1. Boot
2. Push rod
3. Piston and piston cup
4. Spring
5. Cylinder body
6. Solenoid switch
IMPORTANT OPERATIONS
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
CYLINDER BODY
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.
CYLINDER BORE AND PISTON CLEARANCE
1. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. Calculate the clearance between the cylinder bore and the
piston diameter.
If the clearance exceeds the limit, the entire slave cylinde
r
assembly must be replaced.
Cylinder Bore and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.006)
PISTON AND PI STO N CUP
Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts (Repair kit A) shown in
the illustration.
REASSEMBLY
* Apply grease
(COSMO rubber grease)
REASSEMBLY STEPS
▲1. Cylinder body
2. Spring
▲3. Piston and piston cup
4. Push rod
5. Boot
6. Solenoid switch
IMPORTANT OPERATIONS
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.
3. Piston and piston Cup
1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the
illustration.
3) Install the piston and piston cup to the cylinder body .
SLAVE CYLINDER (6VD1 ENGINE)
6VD1
DISASSEM BLY STEPS
1. Boot
2. Push rod
3. Piston and piston cup
4. Spring
5. Cylinder body
REASSEMBLY STEPS
To reassemble, follow disassembly steps in
the reverse order.
DISASSEMBLY
1. Boot
2. Push Rod
3. Piston and Piston Cup
4. Spring
5. Cylinder Body
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
6VD1 CYLINDER BODY
1) Clean the cylinder body.
2) Check the fluid return port for restrictions and clean it i
f
necessary.
6VD1 PISTON AND PI STO N CUP
Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts shown in the illustration.
Measure the clearance between slave cylinder wall and piston
If the measured value exceeds the specified limit, the slave
cylinder assembly must be replaced.
Slave Cylinder Wall and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.0059)
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse
order, noting the following points:
6VD1 1. Piston Assembly
1) Before installing the parts, apply a thin coat of rubbe
r
grease.
2) Ins tall c up in groove in pis ton with the lip turned to the f ront
of cylinder. Use care so as not to scratch the cylinder.
HYDRAULIC DAMPER CYLINDER (EXCEPT 6VD1 ENGINE)
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Visually check for oil leakage and other damage.
If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage
1. CLUTCH SLIPPAG E
Checkpoint Trouble Cause Countermeasure
Adjust the push rod play
No push rod play in the master
cylinder
NG
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Clean the related parts and/or
replace the facing
Repair or replace the
transmission front cover
Adjust the push rod play
Defective transmission front
cover oil seal
Continued on the next page
Grease or oil adhering to the
facing Too much grease
Transmission front cover
unevenly worn
No push rod play in the slave
cylinder
Clean and grease the shift
block
Shift block Insufficient grease on the front
cover contact surfaces
NG
NG
NG
NG
NG
OK
OK
Clutch pedal free play
OK
Checkpoint Trouble Cause Countermeasure
Replace the release bearingRelease bearing broken
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Defective crankshaft rear oil
seal
NG
NG
OK
OK
Grease or oil adhering to the
facing
Clutch diaphragm spring Replace the clutch pressure
plate assembly
Weak or broken clutch
diaphragm spring
Replace the driven plate
assembly
Worn facing
NG
NG
OK
Facing
Continued from the previous page
2. CLUTCH DOES NOT RELEASE PRO PERLY
Checkpoint Trouble Cause Countermeasure
Driven plate Replace the driven plate
Adjust the push rod play
Driven plate warped or
unevenly worn
Too much push rod play in the
slave cylinder
Hydraulic circuit Bleed the hydraulic circuit
Adjust the push rod play
Air in the hydraulic circuit
Too much push rod play in the
master cylinder
OK
NG
NG
NG
NG
OK
Clutch pedal free play
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Corrosion or step wear on the
top gear shaft spline
Pressure plate Replace the pressure plate
assembly
Clean and grease the splined
contact surface
Pressure plate unevenly worn
Insufficient grease on the
spline contact surface of the
splined hub
OK
NG
NG
NG
OK
Continued on the next page
Checkpoint Trouble Cause Countermeasure
Crankshaft pilot bearing Replace the pilot bearing
Top gear shaft wobble is
causing pilot bearing wear
Repair or replace the flywheelFlywheel unevenly worn
NG
NG
OK
OK
Flywheel
Continued from the previous page
3. CLUTCH SHUDDER
Checkpoint Trouble Cause Countermeasure
Grease or oil adhering to the
facing
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Replace the pressure plate
assembly
Defective transmission front
cover oil seal
Pressure plate unevenly worn
Pressure plate
Clean the related parts and/or
replace the facing
Tighten the connections
Repair or replace the
applicable parts
Too much grease
Poorly connected components
causing looseness and
abrasion
OK
NG
NG
NG
NG
OK
Power train
Clean and grease the spline
contact surface
Insufficient grease on the
spline contact surface of the
splined hub
Driven plate
Clean or repair the top gear
shaft spline
Replace the top gear shaft
Clean the related parts and/or
replace the facing
Replace the crankshaft rear oil
seal
Corrosion or step wear on the
top gear shaft spline
Defective crankshaft rear oil
seal
OK
NG
NG
NG
OK
Continued on the next page
Checkpoint Trouble Cause Countermeasure
Replace the driven plate
assembly
Warpage and/or uneven wear
Replace the driven plate
assembly
Loose facing rivets
NG
NG
OK
Driven plate
Continued from the previous page
Flywheel Repair or replace the flywheelFlywheel uneven wear
NG
OK
4. CLUTCH NOISE
1) Clutch Pedal Depressed (Clutch Disengaged)
Checkpoint Trouble Cause Countermeasure
Replace the pedal shaft with
the sleeve
Worn pedal shaft and/or
sleeve
Clean and grease the pedal
shaft and sleeve
Insufficient grease at the
pedal shaft and sleeve
NG
NG
Pedal shaft and sleeve
Master cylinder piston and
push rod contact faces
Clean and grease the master
cylinder piston and push rod
contact faces
Insufficient grease at the
maser cylinder piston and
push rod contact faces
NG
OK
Driven plate Replace the driven plate
assembly
Loose or broken damper
spring
NG
OK
Crankshaft pilot bearing Replace the crankshaft pilot
bearing
Insufficient grease at the
crankshaft pilot bearing (pilot
bearing worn)
NG
OK
2) Clutch Pedal Not Depressed (Clutch Engaged)
Replace the driven plate
Weak or broken damper
spring
NG
Driven plate damper spring
Replace the crankshaft pilot
bearing
Insufficient grease at the
crankshaft pilot bearing (pilot
bearing worn)
OK
NG
Crankshaft pilot bearing
5. OIL LEAKAGE
Checkpoint Trouble Cause Countermeasure
Replace the piston capWeak or damaged piston cap
NG
Tighten the oil pipe
Tighten the oil pipe connection
Tighten the fluid pipe and/or
hose connections
Fluid reservoir Loosely connected oil pipe
Loosely connected oil pipe
Master cylinder fluid pipe and
hose Loosely connected fluid pipe
and/or hose
Slave cylinder oil pipe
Replace the piston cupSlave cylinder Weak or damaged piston cup
NG
NG
NG
NG
OK
OK
OK
OK
Master cylinder
SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME
5-8840-2634-0 Clutch pilot aligner
(HEC Engine Series)
CLL-3 5-8840-0013-0
(J-22888) Bearing puller
(Except 6VD1 Engine)
CLL-4 5-8840-0124-0
(J-2241-11) Bearing puller adapter
(Except 6VD1 Engine)