CLUTCH

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 21-1

CLUTCH
CONTENTS

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5

Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Inspection and Adjustment . . . . . . . . 2
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
21-2 CLUTCH – General Information/Service Specifications/Lubricants/On-vehicle Service

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 212 – 215 <L.H. drive vehicles>
202 – 205 <R.H. drive vehicles>
Clutch pedal clevis pin play mm 1–3
Clutch pedal free play mm 6 – 13
Distance between the clutch pedal and the toeboard 110 or more
when the clutch is disengaged mm

LUBRICANTS
Items Specified lubricants Quantity
Clutch fluid Brake fluid DOT3 or DOT4 As required
Push rod assembly Rubber grease
Release cylinder push rod MITSUBISHI genuine grease
Part No. 0101011

Clutch pedal height Clutch pedal clevis ON-VEHICLE SERVICE

pin play
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 clevis
pin play.
Standard value (A):
A B
212 – 215 <L.H. drive vehicles>
202 – 205 <R.H. drive vehicles>
Standard value (B): 1 – 3 mm
 CLUTCH – On-vehicle Service
Setting nut
Clutch pedal
12 Nm
Clutch pedal free Distance between the
play clutch pedal and the
toeboard when the
clutch is disengaged
C D
Clutch release cylinder
21-3
3. If the clutch pedal height and the clutch pedal clevis pin
play are outside the standard value, turn the setting nut
to adjust them to the standard value.
Caution
Do not push in the master cylinder push rod at this
time, otherwise the clutch will not operate properly.
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 toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6 – 13 mm
Standard value (D): 110 mm or more
5. If the clutch pedal free play and the distance between
the clutch pedal and the 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, release cylinder or clutch. Bleed
the air, or disassemble and inspect the master cylinder,
release cylinder or clutch.
6. Turn back the carpet, etc.
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.
21-4 CLUTCH – Clutch Pedal

CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21-2.)

L.H. drive vehicles R.H. drive vehicles

12 Nm 2 2
12 Nm
4
4
1 1
12 Nm 12 Nm
3 6 3
7
7

Removal steps
1. Snap pin 5. Stopper <R.H. drive vehicles>
2. Clevis pin 6. Pedal pad
3. Clutch master cylinder mounting nut 7. Clutch pedal assembly
4. Master cylinder member mounting bolt
 CLUTCH – Clutch Control 21-5
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Clutch Fluid Draining D Clutch Fluid Supplying
D Clutch Line Bleeding (Refer to P.21-3.)
D Clutch Pedal Adjustment (Refer to P.21-2.)

<L.H. drive vehicles>

13 Nm 6 1
Release fork
Release cylinder
push rod 13 8
7
5 Nm
5

Specified grease:
3
MITSUBISHI genuine
grease Part No. 0101011 4
11 2
19 Nm
5
15 Nm 12 Nm
10
12

11, 13

9
13 5 Nm 20 – 25 Nm
12 Nm

Clutch master cylinder assembly 7. Reservoir tank

removal steps 8. Breather hose
1. Clevis pin Clutch release cylinder assembly
2. Clutch pipe connection removal steps
3. Breather hose connection 9. Clutch pipe connection
4. Clutch master cylinder assembly 10. Clutch release cylinder assembly
5. Sealer
Clutch line removal steps
Reservoir tank removal steps
11. Clutch pipe
3. Breather hose connection 12. Bracket
5. Bolt 13. Clutch hose
6. Reservoir bracket
21-6 CLUTCH – Clutch Control

<R.H. drive vehicles>

2
Release 4
cylinder Release fork
push rod

Specified grease: 3
MITSUBISHI genuine
grease Part No. 0101011 7 12 Nm

15 Nm 19 Nm
6
8

9 12 Nm
5 Nm 20 – 25 Nm

Clutch master cylinder assembly Clutch release cylinder assembly

removal steps removal steps
1. Clevis pin 5. Clutch pipe connection
2. Clutch pipe connection 6. Clutch release cylinder assembly
3. Clutch master cylinder assembly Clutch line removal steps
4. Sealer
7. Clutch pipe
8. Bracket
9. Clutch hose
 CLUTCH – Clutch Control 21-7
DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
Caution
Do not disassemble piston assembly.
6

12 Nm
8
5 9
9
9
3

4
7 1
2
10 7

11

4 2
1
2

Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease

Disassembly steps
1. Piston stopper ring 8. Reservoir tank <R.H. drive vehicles>
2. Piston assembly 9. Seal
"AA 3. Push rod assembly 10. Master cylinder body <L.H. drive
4. Boot vehicles>
5. Nipple <L.H. drive vehicles> 11. Master cylinder body <R.H. drive
6. Reservoir cap <R.H. drive vehicles> vehicles>
7. Spring pin

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.

<L.H. drive vehicles> 103 mm

<R.H. drive vehicles> 126 mm
NOTES