21-1

GROUP 21

CLUTCH
CONTENTS

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A

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CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B
 21A-1

GROUP 21A

CLUTCH
CONTENTS

GENERAL INFORMATION . . . . . . . . 21A-2 CLUTCH PEDAL SWITCH OPERATING CHECK

...................................... 21A-5
SERVICE SPECIFICATION(S) . . . . . 21A-2
CLUTCH MASTER CYLINDER . . . . . 21A-5

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LUBRICANT(S) . . . . . . . . . . . . . . . . . 21A-2 CLUTCH MASTER CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION . . . . . . . . 21A-5
CLUTCH MASTER CYLINDER ASSEMBLY
ON-VEHICLE SERVICE. . . . . . . . . . . 21A-2
DISASSEMBLY AND REASSEMBLY . . . . . 21A-6
CLUTCH PEDAL CHECK AND ADJUSTMENT
CLUTCH MASTER CYLINDER ASSEMBLY
...................................... 21A-2
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-6
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-3
CLUTCH RELEASE CYLINDER . . . . 21A-7
CLUTCH PEDAL . . . . . . . . . . . . . . . . 21A-4
CLUTCH RELEASE CYLINDER ASSEMBLY
CLUTCH PEDAL REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION . . . . . . . . 21A-7
...................................... 21A-4
CLUTCH CONTROL INSPECTION. . . . . . . 21A-7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21A-5
21A-2 CLUTCH
GENERAL INFORMATION

GENERAL INFORMATION
M1211000100308
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.

SERVICE SPECIFICATIONS
M1211000300421

Item Standard value

Clutch pedal height mm 183.5 − 186.5 <LHD>
178.5 − 181.5 <RHD>
Clutch pedal clevis pin play mm 1−3
Clutch pedal free play mm 4 − 13
Distance between the clutch pedal and the floorboard when 91 or more <LHD>
the clutch is released mm 86 or more <RHD>

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LUBRICANTS
M1211000400257

Item Specified lubricant Quantity

Clutch fluid Brake Fluid DOT 3 or DOT 4 As required
Pushrod assembly Rubber grease As required
Release cylinder pushrod MITSUBISHI genuine grease Part As required
No.0101011 or equivalent

ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND 2. Measure the clutch pedal height. If the height is
ADJUSTMENT outside the standard value, go to step 4.
M1211000900940 Standard value (A):
1. Turn back the carpet etc. under the clutch pedal. 183.5 − 186.5 mm <LHD>
Clutch pedal height Clutch pedal clevis pin play 178.5 − 181.5 mm <RHD>
3. Measure the clutch pedal clevis pin play. If the
play is outside the standard value, go to Step 5.
Standard value (B): 1 − 3 mm
4. Remove the clutch switch. (Refer to P.21A-4.)
<Vehicles with cruise control>
A B

AC001133 AD
 CLUTCH
ON-VEHICLE SERVICE
21A-3
CAUTION 8. After the adjustments, confirm that the clutch
Do not push in the master cylinder pushrod at pedal free play (measured at the face of the pedal
this time, otherwise the clutch will not operate pad) and the distance between the clutch pedal
properly. (the face of the pedal pad) and the floorboard
when the clutch is disengaged are within the
standard value ranges.
Adjusting bolt
Standard value (C): 4 − 13 mm
Standard value (D):
Pushrod 91 mm or more <LHD>
86 mm or more <RHD>
Locking nut
9. If the measured free play and distance do not
Clutch pedal agree with the standard value ranges, it is
Setting nut
probably the result of either air in the hydraulic
13 ± 2 N·m
AC502646AC system or a faulty master cylinder or clutch. Bleed
the air, or disassemble and inspect the master
5. If the clutch pedal height is not within the standard cylinder or clutch.
value, loosen the setting nut and the locking nut
10.Reinstall the carpet, etc.
<Vehicles without cruise control> to adjust the
clutch pedal height to the standard value and CLUTCH BLEEDING

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move the pushrod and the adjusting bolt M1211001400733
<Vehicles without cruise control>. CAUTION
6. Install the clutch switch. (Refer to P.21A-4.) Use the specified brake fluid. Do not mix brake
<Vehicles with cruise control> fluids.
7. If the clutch pedal clevis pin play is not within the Specified fluid: Brake fluid DOT 3 or DOT 4
standard value, loosen the setting nut and move
the pushrod to adjust.
Clutch damper
assembly
Clutch pedal free play

Clutch release
C
cylinder assembly AC609129 AC

1. Connect a hose with a bottle to the bleeder screw.

2. Open the bleed nipple.
Distance between the clutch pedal 3. Depress the clutch pedal slowly. Open the bleeder
and the floorboard when the clutch screw to let air and brake fluid out. Close the
is disengaged
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.
4. After air bleeding, tighten the bleeder screw to the
specified torque.
Tightening torque: 8.9 ± 0.9 N⋅m
D
5. Check that the brake fluid reservoir level stays
AC001135AB between "MAX" and "MIN" marks throughout the
clutch bleeding process.
21A-4 CLUTCH
CLUTCH PEDAL

CLUTCH PEDAL
REMOVAL AND INSTALLATION
M1211001601008

Pre-removal Operation Post-installation Operation

• Lower Panel Assembly Removal (Refer to GROUP 52A −
Instrument Panel Assembly ).
• Drivers side under cover <Except vehicles Single cab>
Removal (Refer to GROUP 52A − Instrument Panel
Assembly ).
• ETACS-ECU Removal. <LHD>
• ETACS-ECU Installation. <LHD>
• Drivers side under cover <Except vehicles Single cab>
Installation (Refer to GROUP 52A − Instrument Panel
Assembly ).
• Lower Panel Assembly Installation (Refer to GROUP 52A
− Instrument Panel Assembly ).
• Clutch Pedal Adjustment (Refer to P.21A-2).

6
7 7

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12 ± 2 N·m
13 ± 2 N·m
1 5 <Vehicles with
cruise control>
3
4 <Vehicles without
cruise control>
13 ± 2 N·m 9
13 ± 2 N·m
12 ± 2 N·m

10 N
2 8

AC900934AB

Removal steps INSTALLATION SERVICE POINT

1. Snap pin >>A<< CLUTCH SWITCH <VEHICLES WITH
2. Clevis pin CRUISE CONTROL> INSTALLATION
3. Clutch pedal assembly
4. Adjusting bolt <Vehicles without Clutch switch
cruise control>
>>A<< 5. Clutch switch <Vehicles with cruise
control>
6. Return spring
7. Bushing
8. Stopper
9. Pedal stopper
Clutch pedal
10. Pedal pad 0.5 – 1.0 mm

AC309757AC

Install the clutch switch at the specified dimension

when the clutch pedal is released.
 CLUTCH
CLUTCH MASTER CYLINDER
21A-5
INSPECTION 1. Check for continuity between the terminals of the
switch.
CLUTCH SWITCH CONTINUITY CHECK Tester Plunger Specified
M1211001000263
connection condition condition
CAUTION
Do not apply grease or lubricant to the switch 1-2 Released Continuity (less
and the switch installation section to avoid mal- than 2 Ω)
function of the switch. In addition, do not use Pushed Open circuit
gloves which have grease on them. 2. If the continuity is incorrect, replace the clutch
switch.

Open circuit Continuity

Plunger

Clutch switch 4.0 ± 1.0 mm

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AC807040AB

CLUTCH MASTER CYLINDER

REMOVAL AND INSTALLATION
M1211050100068

Pre-removal Operation Post-installation Operation

Clutch Fluid Draining • Clutch Fluid Supplying
• Clutch Bleeding (Refer to P.21A-3).
• Clutch Pedal Adjustment (Refer to P.21A-2).

1
3 4

15 ± 2 N·m (Except High rider 4WD) 13 ± 2 N·m

18 ± 2 N·m (High rider 4WD)

AC809413AD

Clutch master cylinder removal Clutch master cylinder removal

steps steps (Continued)
• Lower panel assembly (Refer to 2. Clevis pin
GROUP 52A − Instrument Panel 3. Clutch master cylinder assembly
Assembly ). 4. Sealer
1. Snap pin
21A-6 CLUTCH
CLUTCH MASTER CYLINDER

DISASSEMBLY AND REASSEMBLY

M1211002100542

CAUTION
Do not disassemble the piston assembly.

13 ± 2 N·m

6 7
2

1N
3N
5

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8

1 3
3

3
Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease
AC712190 AB

Disassembly steps REASSEMBLY SERVICE POINT

1. Piston stopper ring
>>A<< 2. Pushrod assembly
3. Piston assembly
4. Reservoir cap
5. Spring pin
6. Reservoir tank
7. Seal
8. Master cylinder body

120.4 122.4 mm
AC800214AB

>>A<< PUSHROD ASSEMBLY INSTALLATION

Set the length of the pushrod assembly to the dimen-
sion shown to make the adjustment of the clutch
pedal easier.

INSPECTION
M1211002200196
• Check inside the cylinder body for rust and scars.
• Check the piston for rust and scars.
• Check the pipe connection for clogging.
 CLUTCH
CLUTCH RELEASE CYLINDER
21A-7
CLUTCH RELEASE CYLINDER
REMOVAL AND INSTALLATION
M1211005500129

Pre-removal Operation Post-installation Operation

Clutch Fluid Draining • Clutch Fluid Supplying
• Clutch Bleeding (Refer to P.21A-3).
• Clutch Pedal Adjustment (Refer to P.21A-2).

<Except High rider, 4WD)> <High rider, 4WD>

9 30 ± 3 N·m 23 ± 2 N·m
15 ± 2 N·m 8 10 6N
8 5
9 10 4 15 ± 2 N·m
7
15 ± 2 N·m
4
48 ± 6 N·m
30 ± 3 N·m 11 ± 2 N·m 3 11 ± 2 N·m 18 ± 2 N·m
1
23 ± 2 N·m
48 ± 6 N·m
6N 7 2N

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5 35 ± 6 N·m
3 23 ± 2 N·m
1 Release fork
35 ± 6 N·m N 2 23 ± 2 N·m

Release cylinder
3 pushrod
Specified grease:
MITSUBISHI genuine grease
PART No. 0101011 or equivalent
AC903922AB

Clutch release cylinder assembly Clutch release cylinder assembly

and clutch damper assembly and clutch damper assembly
removal steps removal steps (Continued)
• Side rubber cover rear (front 8. Clutch damper assembly
wheelhouse left side). 9. Clutch damper bracket
1. Eye bolt 10. Clutch damper
2. Gasket
3. Clutch release cylinder assembly INSPECTION
M1211002000200
4. Clutch pipe
• Check the clutch fluid line for fluid leakage.
5. Eye bolt
6. Gasket
• Check the clutch hose and pipe for cracks or
7. Clutch hose clogging.
 21B-1

GROUP 21B

CLUTCH
OVERHAUL
CONTENTS

GENERAL SPECIFICATIONS . . . . . . 21B-2 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 21B-3

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CLUTCH REMOVAL AND INSTALLATION 21B-3
SERVICE SPECIFICATIONS. . . . . . . 21B-2 CLUTCH INSPECTION . . . . . . . . . . . . . . . . 21B-5

TORQUE SPECIFICATIONS . . . . . . . 21B-2 CLUTCH RELEASE CYLINDER . . . . 21B-6

CLUTCH RELEASE CYLINDER DISASSEMBLY AND
LUBRICANTS . . . . . . . . . . . . . . . . . . 21B-2 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21B-6
CLUTCH RELEASE CYLINDER INSPECTION
...................................... 21B-7
21B-2 CLUTCH OVERHAUL
GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
M1212000201356

Item R5MB1-J-ND1 R5MB1-J-NC,V5MB1

Clutch operating method Hydraulic type
Clutch disc type Single dry disc type
Clutch disc size O.D. × I.D. mm 225 × 150 250 × 160
Clutch cover type Diaphragm spring type
Clutch cover setting load N 5,394 ± 441 5,850 ± 470

SERVICE SPECIFICATIONS
M1212000300286

Item Limit
Diaphragm spring end height difference mm 0.5
Facing rivet sink mm 0.3

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Release cylinder I.D. to piston O.D. clearance mm 0.15

TORQUE SPECIFICATIONS
M1212001800347

Item N⋅m
Fulcrum 35 ± 6
Clutch release cylinder mounting bolt 35 ± 6
Clutch cover mounting bolt 19 ± 3
Air bleeder 8.0 ± 1.0

LUBRICANTS
M1212000400681

Items Specified lubricants Quantity

Clutch release bearing to release fork Mitsubishi Part No. 0101011 or equivalent As required
contact surface
Fulcrum to release fork contact surface
Clutch release cylinder push rod to release
fork contact surface
Clutch release bearing inside
Clutch disc spline
Clutch release cylinder inner surface Brake Fluid DOT 3 or DOT 4
Piston and piston cups outer surface Rubber grease
 CLUTCH OVERHAUL
CLUTCH
21B-3
CLUTCH
DISASSEMBLY AND REASSEMBLY
M1212001001065

3
1
2 4 7

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8
35 ± 6 N·m

19 ± 3 N·m

35 ± 6 N·m 6

AK403591AB

Removal steps DISASSEMBLY SERVICE POINT

>>C<< 1. Clutch cover <<A>> RELEASE FORK REMOVAL
>>C<< 2. Clutch disc
3. Return clip
>>B<< 4. Clutch release bearing
5. Clutch release cylinder Fulcrum
6. Boot
<<A>> >>A<< 7. Release fork Clip
8. Fulcrum

Release fork

AK403602 AB

Slide the release fork in direction of the arrow and

disengage the fulcrum from the clip to remove the
release fork. Be careful not to damage the clip by
pushing the release fork in the wrong direction or
removing it with force.
21B-4 CLUTCH OVERHAUL
CLUTCH

REASSEMBLY SERVICE POINTS 3. Install the return clip to engage the clutch release
>>A<< RELEASE FORK INSTALLATION bearing with the fork.

>>C<< CLUTCH DISC / CLUTCH COVER

INSTALLATION

Flywheel
Clutch disc

Fulcrum

Release fork

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Clutch disc guide

Clutch release cylinder

AK403592AB Clutch cover
1. Apply the specified grease to the release fork.
Specified grease: Mitsubishi Part No. AK403594AB
0101011 or equivalent
1. Apply the specified grease to the clutch disc
2. Install the release fork onto the fulcrum. splines and rub it in splines with a brush.
Specified grease: Mitsubishi Part No.
>>B<< CLUTCH RELEASE BEARING 0101011 or equivalent
INSTALLATION
2. Using the clutch disc guide to position the clutch
disc on the flywheel.

8 1

5 3

4 6
AK503501AB :
Dowel pin
1. Apply the specified grease to the clutch release position 2 7 AK500601AE
bearing inside, and fill grease in the groove.
3. Install the clutch cover, aligning its installation
Specified grease: Mitsubishi Part No.
position with the dowel pins, and then tighten the
0101011 or equivalent
bolts to the specified torque of 19 ± 3 N⋅m in the
2. Install the clutch release bearing on the bearing order shown in the illustration.
retainer of the transmission.
 CLUTCH OVERHAUL
CLUTCH
21B-5
INSPECTION 1. Check the facing for loose rivets, uneven contact,
M1212001100252 deterioration due to seizure, adhesion of oil or
CLUTCH COVER grease. Replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc
Diaphragm spring if it is out of specification.
Limit: 0.3 mm
3. Check for the torsion spring play and damage. If
defective, replace the clutch disc.
4. Combine the clutch disc with the input shaft and
check sliding condition and play in the rotating
direction. If it does not slide smoothly or the play
AK403603AB
is excessive, check after cleaning and
reassembling. If the play is excessive, replace the
1. Check the diaphragm spring end for wear and clutch disc and/or the input shaft.
uneven height. Replace if wear is evident or
height difference exceeds the limit. CLUTCH RELEASE BEARING
Limit: 0.5 mm CAUTION
2. Check the pressure plate surface for wear, cracks The clutch release bearing is packed with grease.

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and seizure. Do not wash it in cleaning solvent.
3. Check the strap plate rivets for looseness and 1. Check the bearing for seizure, damage, noise, or
replace the clutch cover assembly if loose. improper rotation. If defective, replace the
bearing.
CLUTCH DISC 2. Check for wear on the surface which contacts with
the diaphragm spring. If abnormally worn, replace
CAUTION
the bearing.
Don't clean the clutch disc in a cleaning solvent.
3. Check for wear on the surface which contacts with
the release fork. If abnormally worn, replace the
bearing.
Rivet sink
RELEASE FORK
Check for wear on the surface which contacts with
the bearing. If abnormally worn, replace the release
fork.

AK400613 AC
21B-6 CLUTCH OVERHAUL
CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER

DISASSEMBLY AND REASSEMBLY
M1212001500573

4
7 1
8.0 ± 1.0 N·m

8 2

9 3

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5
6

AK503444 AE

Disassembly steps DISASSEMBLY SERVICE POINT

1. Push rod <<A>> PISTON CUP A / PISTON CUP B / PISTON
2 Boot REMOVAL
<<A>> >>A<< 3. Piston cup B
<<A>> >>A<< 4. Piston WARNING
<<A>> >>A<< 5. Piston cup A • Cover with a shop towel to prevent the
6. Conical spring piston from popping out.
7. Cap • Apply compressed air slowly to prevent
8 Bleeder plug
brake fluid from splashing.
>>A<< 9. Release cylinder

AK102083

Remove the piston and piston cup from the release

cylinder using compressed air.
 CLUTCH OVERHAUL
CLUTCH RELEASE CYLINDER
21B-7
REASSEMBLY SERVICE POINT 2. Apply grease to the piston and piston cups and
>>A<< RELEASE CYLINDER / PISTON CUP A / insert the piston assembly into the release
PISTON CUP B / PISTON INSTALLATION cylinder.
Specified grease: Rubber grease

INSPECTION
M1212001600246
PISTON CUP
Check the lip of piston cup for scratch. If there are
any scratches, check if there are any scores inside
the release cylinder.

RELEASE CYLINDER
AK704100AB
1. Check the inner surface of the release cylinder for
1. Apply brake fluid to the entire inner surface of the rust or scratches.
release cylinder. 2. Use a cylinder gauge to measure the inside
Specified brake fluid: Brake fluid DOT 3 or diameter of the release cylinder at three different
DOT 4 points (innermost, middle, and outermost points).
Replace the release cylinder assembly if the

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clearance between the piston and cylinder
exceeds the limit at any of the measurement
points.
Limit: 0.15 mm

Piston Piston cup

AK203875 AH