21A-1

GROUP 21A

CLUTCH
CONTENTS

GENERAL INFORMATION . . . . . . . . 21A-2 CLUTCH SWITCH CHECK AND ADJUSTMENT

...................................... 21A-4
SERVICE SPECIFICATIONS. . . . . . . 21A-2
CLUTCH PEDAL. . . . . . . . . . . . . . . . . 21A-5
LUBRICANTS . . . . . . . . . . . . . . . . . . 21A-2 REMOVAL AND INSTALLATION . . . . . . . . 21A-5

ON-VEHICLE SERVICE. . . . . . . . . . . 21A-2 CLUTCH CONTROL . . . . . . . . . . . . . . 21A-7

CLUTCH PEDAL CHECK AND ADJUSTMENT REMOVAL AND INSTALLATION . . . . . . . . 21A-7
...................................... 21A-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-9
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-3 DISASSEMBLY AND REASSEMBLY . . . . . 21A-10
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-11
21A-2 CLUTCH
GENERAL INFORMATION

GENERAL INFORMATION
M1211000100212
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control. The
clutch shares a brake fluid reservoir with the brake
system.

SERVICE SPECIFICATIONS
M1211000300205

Item Standard value

Clutch pedal height mm LH drive vehicles 226 − 229
Clutch pedal height mm RH drive vehicles 254 − 257
Clutch pedal clevis pin play mm 1−3
Clutch pedal free play mm 4 − 13
Distance between the clutch pedal and the clutch pedal LH drive vehicles 30 or more
stopper when the clutch is disengaged mm
Distance between the clutch pedal and the clutch pedal RH drive vehicles 30 or more
bracket when the clutch is disengaged mm

LUBRICANTS
M1211000400183

Item Specified lubricant Quantity

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

ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND Clutch pedal height
ADJUSTMENT
M1211000900274
1. Turn up the carpet, etc. under the clutch pedal.

AC312890AB

2. Measure the clutch pedal height.

Standard value (A): 226 − 229 mm <LH drive
vehicles>, 254 − 257 mm <RH drive vehicles>
 CLUTCH
ON-VEHICLE SERVICE
21A-3

Clutch pedal clevis pin play Clutch pedal free play

B C

AC100355 AB AC100355 AC

3. Measure the clutch pedal clevis pin play.

Standard value (B): 1 − 3 mm

Setting nut

Clutch pedal
12 ± 2 N·m
AC100356 AD
CAUTION
Do not push in the master cylinder pushrod at
this time, otherwise the clutch will not operate
properly.
4. If the clutch pedal height and clutch pedal clevis
pin play are not within the standard value, loosen
the setting nut to adjust the clutch pedal height
and clevis pin play to the standard value.
AC312891AB
5. 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 when the clutch is disengaged are
within the standard value ranges.
Standard value (C): 4 − 13 mm
Standard value (D): 30 mm or more
6. If the clutch pedal free play and the distance
between 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,
release cylinder or clutch. Bleed the air, or
disassemble and inspect the master cylinder,
release cylinder or clutch.

CLUTCH BLEEDING
M1211001400205

CAUTION
Use the specified brake fluid. Do not mix brake
fluids.
Specified fluid: Brake fluid DOT 3 or DOT 4
21A-4 CLUTCH
ON-VEHICLE SERVICE

1
2

AC310878 AB AC310877

1. Connect a hose with a bottle to the bleeder screw. 2. Connect an ohmmeter to the clutch switch
2. Open the bleed nipple. connector, and then check for continuity when the
clutch pedal is fully depressed and when it is
3. Depress the clutch pedal slowly. Open the bleeder released outward.
screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat Tester Pedal position Specified
until only brake fluid and no air comes out. connection condition
4. Check that the brake fluid reservoir level stays 1-2 Fully depressed Less than 2 Ω
between "MAX" and "MIN" marks throughout the Released Open circuit
clutch bleeding process.
3. If the continuity is incorrect, replace the clutch
switch.
CLUTCH SWITCH CHECK AND
ADJUSTMENT
M1211001100196
1. Adjust the clutch pedal.
 CLUTCH
CLUTCH PEDAL
21A-5
CLUTCH PEDAL
REMOVAL AND INSTALLATION
M1211001600221

Post-installation Operation
• Clutch Pedal Adjustment (Refer to P.21A-2).

<LH drive vehicles>

5
12 ± 2 N·m

3
6

12 ± 2 N·m

1 7
12 ± 2 N·m
4 2
<RH drive vehicles> 10
8

9
5
12 ± 2 N·m

2 6
12 ± 2 N·m
1 7
12 ± 2 N·m
4
10
9
8

AC311081AB

Removal steps Removal steps (Continued)

• Instrument panel under cover 5. Clutch pedal assembly mounting
(Refer to GROUP 52A, Instrument bolt
panel P.52A-2). >>A<< 6. Clutch switch
1. Stopper 7. Nut
2. Snap pin 8. Pedal pad
3. Clevis pin 9. Pedal stopper
4. Clutch master cylinder mounting 10. Clutch pedal assembly
nut
21A-6 CLUTCH
CLUTCH PEDAL

INSTALLATION SERVICE POINT Install the clutch switch at the specified dimension
when the clutch pedal is released.
>>A<< CLUTCH SWITCH INSTALLATION
Clutch switch

Clutch pedal 0.5 – 1.5 mm

AC309757AB
 CLUTCH
CLUTCH CONTROL
21A-7
CLUTCH CONTROL
REMOVAL AND INSTALLATION
M1211001900222

Pre-removal Operation Post-installation Operation

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

<LH drive vehicles>

Release fork 15 ± 2 N·m

11, 15, 17
Release cylinder
13 push rod

Specified grease:
MITSUBISHI genuine grease
PART No. 0101011
1 4
7
5 6

12 ± 2 N·m 14

11 17
19 12 ± 2 N·m
9N 8
2 30 ± 4 N·m
3 15
13 16 12 ± 2 N·m

18
12 ± 2 N·m

18 ± 3 N·m

11 12
10 AC311217 AB

Clutch master cylinder removal Clutch master cylinder removal

steps steps (Continued)
1. Reservoir hose and brake fluid • Brake master cylinder assembly
reservoir connection and brake booster (Refer to
2. Clutch damper bracket GROUP 35A, Master cylinder
3. Clutch tube and clutch damper assembly and brake
assembly connection boosterP.35A-14.)
4. Clevis pin
5. Clutch master cylinder
6. Sealer
>>B<< 7. Reservoir hose
21A-8 CLUTCH
CLUTCH CONTROL

Clutch master cylinder removal

steps (Continued)
8. Eye bolt
9. Gasket
Clutch release cylinder removal
steps
10. Clutch tube and clutch orifice
assembly
11. Clutch tube
12. Clutch orifice assembly
13. Clutch release cylinder
Clutch line removal steps
>>A<< 14. Clutch hose
15. Clutch tube
16. Clutch damper assembly
17. Clutch tube
18. Clutch hose bracket
19. Clutch hose

<R.H. drive vehicles>

1
3 5

Release fork
12 ± 2 N·m

4
2
Release cylinder
push rod 10
9
Specified grease: 7
MITSUBISHI genuine grease 12
PART No. 0101011 or equivalent
12 ± 2 N·m

9
11

18 ± 3 N·m

15 ± 2 N·m
7 8
6
7, 10
AC311218 AB
 CLUTCH
CLUTCH CONTROL
21A-9
Clutch master cylinder removal
steps >>B<< RESERVOIR HOSE INSTALLATION
1. Clevis pin
2. Clutch tube connection <LH drive vehicles>
>>B<< 3. Reservoir hose
Marking
4. Clutch master cylinder
5. Sealer
Clutch release cylinder removal
steps
6. Clutch tube and clutch orifice
assembly
7. Clutch tube Reservoir Marking
8. Clutch orifice assembly hose
9. Clutch release cylinder AC310973 AB

Clutch line removal steps

10. Clutch tube <RH drive vehicles>
11. Clutch hose bracket Marking
12. Clutch hose

INSATALLATION SERVICE POINT Reservoir

>>A<< CLUTCH HOSE INSTALLATION hose

Marking
Clutch hose plate

AC310974 AB

Install the reservoir hose with the marking as shown

in the illustration.

INSPECTION
M1211002000158
Master cylinder • Check the master cylinder or clutch hose for fluid
salience AC310972 AB leakage.
• Check the clutch hose or tube for cracks or
Install the clutch hose so that the clutch hose plate
clogging.
will touch the master cylinder salience.
21A-10 CLUTCH
CLUTCH CONTROL

DISASSEMBLY AND REASSEMBLY

M1211002100229
CLUTCH MASTER CYLINDER
CAUTION
Do not disassemble the piston assembly.

<RH drive vehicles> <LH drive vehicles>

12 ± 2 N·m
6
6

7 7 3
4 N
1N
2N
5
5

9N 8
8

10
2

4 2
1
2

3
4
Clutch fluid:
Piston repair kit Brake fluid DOT3 OR DOT4 Grease: Rubber grease

AC310984 AB

Disassembly steps REASSEMBLY SERVICE POINT

1. Piston stopper ring
>>A<< PUSHROD ASSEMBLY
2. Piston assembly
>>A<< 3. Pushrod assembly INSTALLATION
4. Boot
5. Spring pin
6. Nipple
7. Seal
8. Master cylinder body
9. Gasket
10. Damper assembly

112.8 ± 0.5 mm
AC001144 AH
 CLUTCH
CLUTCH CONTROL
21A-11
Set the length of the pushrod assembly to the INSPECTION
dimension shown to make the adjustment of the M1211002200152

clutch pedal easier. • Check inside the cylinder body for rust and scars.
• Check the piston for rust and scars.
• Check the pipe connection for clogging.