GROUP 21B CLUTCH

<C14W40T>

SPECIFICATIONS ........................................................................... 21B-2

STRUCTURE AND OPERATION

1. Clutch Control .......................................................................... 21B-2
2. Clutch Master Cylinder ............................................................. 21B-3
3. Clutch Booster .......................................................................... 21B-4
4. Clutch Proper ............................................................................21B-6

TROUBLESHOOTING .................................................................... 21B-8

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Replacement of Clutch Fluid .................................................... 21B-10
2. Air Bleeding of Clutch Fluid ..................................................... 21B-12
3. Inspection of Clutch Booster Function ................................... 21B-14
4. Inspection and Adjustment of Clutch Pedal ............................ 21B-14
5. Clearance between Clutch Pedal and Floor ............................. 21B-16
6. Clutch Action .......................................................................... 21B-17
7. Applying Grease to Clutch Controls ....................................... 21B-17

CLUTCH PEDAL ........................................................................... 21B-18

CLUTCH MASTER CYLINDER .................................................... 21B-20

CLUTCH BOOSTER ..................................................................... 21B-22

CLUTCH PROPER .........................................................................21B-30

CLUTCH CONTROL ..................................................................... 21B-42

21B-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Model C14W40T
Clutch model
Type Pull type
Drive type Strap drive
Clutch disc Model Dry, twin plate type
Pressure plate Model Diaphragm spring type
Control system Combined use of fluid pressure and air pressure
Clutch master cylinder Manufacturer Nabtesco
Type Adjustable
Clutch booster
Manufacturer Bosch

STRUCTURE AND OPERATION

1. Clutch Control

• Both fluid pressure and air pressure are used to control the clutch operation.
• When the clutch pedal is pressed, a force is applied to the push rod of the clutch master cylinder, pushing the pis-
ton in the clutch master cylinder. As a result, fluid pressure is generated, activating the clutch booster and disen-
gaging the clutch.

21B-2
 21B
2. Clutch Master Cylinder

2.1 Before clutch pedal is pressed

• Because the piston is pushed against
the push rod by the return spring, the
supply valve rod contacts the supply
valve stopper, leaving the supply valve
open.
• As a result, the fluid passage on the
fluid tank side is connected to the fluid
passage on the clutch booster side.

2.2 When clutch pedal is pressed

• When the push rod pushes the piston,
the supply valve rod leaves the supply
valve stopper, and at the same time,
the spring force of the supply valve
spring closes the supply valve.
• When the piston is further pushed, the
fluid pressure is generated in the cylin-
der, which activates the clutch booster.
• As a result, the fluid is supplied by the
movement amount of the piston.
2.3 When clutch pedal is released
• When the piston is pushed back by the
fluid pressure in the cylinder and the
return spring, the supply valve rod
contacts the stopper, opening the sup-
ply valve.
• As a result, the fluid on the clutch
booster side returns to the fluid tank,
and fluid pressure is lost.

21B-3
STRUCTURE AND OPERATION
3. Clutch Booster
T

3.1 Before clutch pedal is pressed

• Both the air chamber and control
chamber are in an atmospheric pres-
sure condition.
• Therefore, the relay piston is pushed
to the left direction by a force of spring
B, creating clearance between the re-
lay piston and intake valve.
• As this clearance allows the control
chamber to be connected to chamber
A of the cylinder shell, chamber A is
also in an atmospheric pressure con-
dition.
• Chamber B is also in an atmospheric
pressure condition because it is con-
nected to the air chamber. Therefore,
there is no pressure difference be-
tween chamber A and chamber B of
the cylinder shell.
• As a result, the piston plate is kept
pushed to the left side by spring A and
the release fork shaft on the clutch
side.

21B-4
 21B
3.2 When clutch pedal is pressed
• The fluid pressure from the clutch
master cylinder acts on the hydraulic
piston and relay piston.
• Pushed to the right by the fluid pres-
sure, the relay piston is brought into
intimate contact with the poppet valve,
closing the clearance.
• As a result, the passage that was
formed between the control chamber
and chamber A up to now is shut off.
• The relay piston further pushes the
poppet valve, creating clearance be-
tween the poppet valve and the upper
valve body.
• The air pressure enters chamber A
through this clearance, creating differ-
ential pressure between chamber A
and chamber B.
• This differential pressure works as a
force to push the piston plate to the
right direction. As this force is com-
bined with the fluid pressure applied to
the hydraulic piston, the clutch can be
disengaged with light pedal effort.

3.3 When clutch pedal is released

• The fluid pressure acting on the hy-
draulic piston and relay piston is lost,
and each piston is in a free condition.
• As a result, the relay piston and pop-
pet valve are returned to the left direc-
tion by the force of springs B and C.
• The poppet valve is brought into inti-
mate contact with the upper valve
body, shutting off the air passage to
chamber A, and instead creating
clearance to the relay piston.
• As this clearance allows the air cham-
ber to be connected to the control
chamber and chamber A, air pressure
in chamber A is released to the atmo-
sphere from the exhaust cover, elimi-
nating pressure difference between
chamber A and chamber B. The piston
plate is returned to the left by spring A
and the release fork shaft on the
clutch side, returning to the non-oper-
ative position.

21B-5
STRUCTURE AND OPERATION
3.4 When air system fails
• When no air pressure from the air tank
is supplied, there is no air pressure to
chamber A.
• As a result, the piston plate is returned
to the left direction by the force of
spring A.
• Therefore, the clutch is disengaged
only by the fluid pressure applied to
the hydraulic piston.

4. Clutch Proper

21B-6
 21B
4.1 When clutch pedal is released
• Pressure plate presses and intermedi-
ate plate clutch disc against flywheel
by the spring force of diaphragm
spring.
• Clutch disc pressed against flywheel
and intermediate plate rotates togeth-
er with the flywheel and intermediate
plate, transmitting a driving power to
drive pinion of the transmission.

4.2 When clutch pedal is pressed

• Fluid pressure generated in the clutch
master cylinder actuates the clutch
booster. This causes release fork shaft
to actuate release fork, and also pulls
clutch shifter, release bearing and dia-
phragm spring as a whole unit.
• Diaphragm spring pulls back pressure
plate using wire ring as a fulcrum. Be-
cause of this, a clearance is created
between clutch disc and flywheel and
intermediate plate, and the engine
power is therefore not transmitted to
the transmission.

21B-7
TROUBLESHOOTING
Symptoms

Clutch makes noise on disengagement

Clutch pedal requires too much effort

Clutch makes noise on engagement
Clutch does not engage smoothly
Clutch disengaged but drags

Judder when vehicle starting

Reference
Gr

Clutch slips
Possible causes
Uneven diaphragm spring height O O O O
Pressure plate distorted or faulty O O O O
Clutch cover Diaphragm spring fatigued O O O
Loose strap bolt O
Clutch cover set Bent strap plate O
Release bearing faulty O O
Release
Clutch shifter sliding faulty O O O O
bearing
Poor lubrication of clutch shifter O O O O
Intermediate plate distorted or faulty O O O O
Disc deformed O O O
Disc rivets loose O O
Disc torsion spring fatigued or damaged O
Spline worn O O O
Clutch disc
Spline rusted O O O
Facing worn O
Facing surface hardened O O O
Facing oily or greasing O O
Pedal free play insufficient O O
Pedal free play excessive O
Clutch pedal Pedal stroke insufficient O
Return spring fatigued O
Pedal sliding part faulty O O O
Piston and piston cup sliding movement faulty O O O
Spring fatigued O O O
Clutch booster Clutch fluid port clogged O O O
Low air pressure O O
Malfunctioning O O O
Piston and piston cup sliding movement faulty O O O O
Clutch master cylinder Spring fatigued O O O
Clutch fluid passage port clogged O O O
Release fork deformed O O O
Clutch housing
Needle roller bearing sliding faulty O O
Transmission drive pinion or input shaft splines worn O O Gr22B
Engine mounting fatigued O
Flywheel warped, deformed or worn forming steps O O O O Gr11
Flywheel pilot bearing faulty O
Air mixed in clutch fluid O
Clutch fluid leaking O

21B-8
 21B
M E M O

21B-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Replacement of Clutch Fluid
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
– Air bleeder 6.9 to 13 {0.7 to 1.3} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Brake fluid (SAE J1703 or FMVSS
– Clutch fluid tank As required
No.116 DOT3)

CAUTION
• Be sure to use new Brake Fluid (SAE J1703 or FMVSS No.116 DOT3). Do not mix it with brake fluid of dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter the original properties of Brake Fluid, causing the boiling point to drop as well as the clutch rubber
parts to swell. Faulty operation of the clutch will result. Use a mug exclusively kept for the specified brake
fluid. This ensures that no brake fluid of different properties or mineral oil enter into the system.
• Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty
clutch operation.
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork.
• If brake fluid is spilled onto the paintwork, immediately wipe it off.

1.1 Work before replacement

• Install one end of a vinyl pipe onto the air bleeder of the clutch
booster. Place the loose end into a container.

21B-10
 21B
1.2 Replacement of clutch fluid
• Carry out replacement of clutch fluid following the flow chart be-
low.
• Replacement of old clutch fluid with new clutch fluid in the clutch
fluid line can be recognized by a change in color of the clutch flu-
id being discharged through the vinyl pipe.

Replacement flow chart

Loosen the air bleeder.

Press and release the clutch pedal repetitively until

clutch fluid is no longer discharged.

Fill clutch fluid up to the “H” level on the clutch fluid tank.

Tighten the air bleeder.

Cycle the clutch pedal several times, then press and

hold the pedal.

Loosen the air bleeder to discharge the clutch fluid.

Air in clutch fluid No air in clutch fluid

Tighten the air bleeder.

Release the clutch pedal and wait for at least

one second.

Add clutch fluid up to the “H” level on the tank.

Tighten the air bleeder to the specified torque.

Release the clutch pedal.

Add clutch fluid up to the “H” level on the tank.

Finish

21B-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
2. Air Bleeding of Clutch Fluid
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
– Air bleeder 6.9 to 13 {0.7 to 1.3} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Brake fluid (SAE J1703 or FMVSS
– Clutch fluid tank As required
No.116 DOT3)

CAUTION
• Be sure to use new Brake Fluid (SAE J1703 or FMVSS No.116 DOT3). Do not mix it with brake fluid of dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter the original properties of Brake Fluid, causing the boiling point to drop as well as the clutch rubber
parts to swell. Faulty operation of the clutch will result. Use a mug exclusively kept for the specified brake
fluid. This ensures that no brake fluid of different properties or mineral oil enter into the system.
• Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty
clutch operation.
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork.
• If brake fluid is spilled onto the paintwork, immediately wipe it off.

2.1 Work before air bleeding

• Install one end of a vinyl pipe onto the air bleeder in the clutch
booster. Place the loose end into a container as in the replace-
ment procedure.

21B-12
 21B
2.2 Air bleeding of clutch fluid
• Carry out air bleeding of clutch fluid following the flow chart be-
low.
• When air pressure warning lamp in the meter cluster illumi-
nates during work, start the engine to fully charge air pressure.
• When no fluid changer (pumping machine) is used, remove the
clutch fluid tank, and secure it 35 mm above or higher in a sim-
ple way.
• Replenish clutch fluid as necessary during work so that clutch
fluid in the clutch fluid tank is always between “H” and “L”.

Air bleeding flow chart

Fill clutch fluid up to the “H” level on the clutch fluid tank.

Cycle the clutch pedal several times, then press and

hold the pedal.

Loosen the air bleeder to discharge the clutch fluid.

Air in clutch fluid No air in clutch fluid

Tighten the air

bleeder.

Release the clutch

pedal and wait for at
least one second.

Tighten the air bleeder to the specified torque.

Release the clutch pedal.

Add clutch fluid up to the “H” level on the tank.

Finish

21B-13
ON-VEHICLE INSPECTION AND ADJUSTMENT
3. Inspection of Clutch Booster Function
• If any abnormality is caused during the following inspection, per-
form overhauling of the clutch booster. (See “Clutch booster”.)
(1) Clutch pedal effort
• Make sure that the clutch pedal effort is heavy at the air pres-
sure of 0 kPa {0 kgf/cm2} and that it becomes light at the air
pressure of 590 to 785 kPa {6 to 8 kgf/cm2}.
(2) Air discharge
• Make sure that air is discharged from the exhaust cover when
the clutch pedal is released from the pressed condition.

(3) Air leakage

• Set the air pressure to 590 to 785 kPa {6 to 8 kgf/cm2}, and hang
a thread onto the exhaust cover.
• Make sure that the thread is not blown up into the air when the
clutch pedal is released and pressed.
If the thread is blown up, air leaks from the poppet valve.

4. Inspection and Adjustment of Clutch Pedal

• Perform inspection and adjustment of clutch pedal after finishing air bleeding in clutch system.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
– Clutch pedal full stroke 190 ± 5 – Replace
– Clutch master cylinder push rod play (clutch pedal play) 1.0 (6 ± 1) – Adjust or replace
– Clutch booster push rod play 4.4 – Adjust or replace
Clutch pedal play
– (clutch master cylinder push rod play and clutch boost- 30 to 41 – Adjust or replace
er push rod play)

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Lock nut 9.8 to 15 {1.0 to 1.5} –

21B-14
 21B
4.1 Clutch pedal full stroke
[Inspection]
• Measure the full stroke between the released pedal position and
the fully pressed pedal position with the engine stopped. The
measuring is performed at the pedal pad center.
• It the measurement value is out of the standard value, adjust the
full stroke by turning the clutch switch.
[Adjustment]
• Adjust the full stroke by turning the clutch switch so that the
stroke conforms to the standard value. After adjustment, tighten
the nut to fix the clutch switch.
• After tightening the nut, measure the full stroke again.
• If the measured value is out of the standard value, replace the
clutch pedal.

4.2 Clutch pedal play

• Clutch pedal play is the combination of play on the clutch pedal
side (clutch master cylinder push rod play) and play on the
clutch proper side (clutch booster push rod play), and can be
checked in the following manner.

(1) Clutch master cylinder push rod play (clutch pedal play)
[Inspection]
• If the measurement is to be performed immediately following the
completion of air bleeding, cycle the clutch pedal several times
before the measurement to allow the components to settle. Oth-
erwise, the push rod play normally measures smaller than it ac-
tually does.
• Gently push the clutch pedal with a finger until it comes to the
first stop. While doing that, measure the play A that the push rod
has traveled or the play B that the pedal has traveled.
• If the measurement does not conform to the standard value, ad-
just as follows.
[Adjustment]
• Loosen the lock nut and adjust by rotating the push rod.
• After adjustment, tighten the lock nut to the specified torque.

21B-15
ON-VEHICLE INSPECTION AND ADJUSTMENT
(2) Clutch booster push rod play
[Inspection]
• If the measurement is to be performed immediately following the
completion of air bleeding, cycle the clutch pedal several times
before the measurement to allow the components to settle. Oth-
erwise, the push rod play normally measures smaller than it ac-
tually does.
• Remove the return spring. Then, move the push rod with hand
while measuring the push rod play.
• If the measurement does not conform to the standard value, ad-
just as follows.
[Adjustment]
• Loosen the nuts. Then, extend the push rod until it comes to a
stop by rotating the hexagonal part of the rod.
• Retract the rod by rotating the hexagonal part by approximate 4
turns. Tighten the nuts.
• If the dimension A in the illustration is less than 67 mm, this
means that the clutch disc is worn beyond the limit. Replace the
clutch disc.
• After adjustment, install the return spring.

(3) Clutch pedal play

[Inspection]
• Push the clutch pedal by hand and measure the movement
amount (play of push rod of clutch master cylinder and play of
push rod of clutch booster) until resistance is felt.
• If the measured value deviates from the standard value, readjust
clutch pedal play or replace clutch faulty parts.

5. Clearance between Clutch Pedal and Floor

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
– Clearance between clutch pedal and floor 75 or more – Adjust or replace

• Perform the following inspection with two persons to establish

the position at which the clutch is about to reengage.
• Remove the lower driver inner panel. (See Gr52.)
• Apply the chocks to the wheels and the parking brake. Run the
engine at idle.
• Pressing the clutch pedal, shift the gear shift lever to the forward
highest gear position.
• Gradually release the clutch pedal, and measure the clearance
between the pedal and floor just before the clutch is engaged.
WARNING
• Be careful not to allow the vehicle from starting suddenly.
Pay full attention to the surrounding condition.

• If the measured value is less than the standard value, repeat the
adjustment of the play of clutch pedal or replace faulty parts.

21B-16
 21B
6. Clutch Action
• Check that pressing the clutch pedal does not create any abnormal noise or require excessive effort.
• Check that gear shifting can be performed easily with the clutch pedal pressed. Check also that the clutch en-
gagement is smooth and without any drag as the pedal is gradually released.
• If any abnormality is encountered, repair or replace faulty parts.

7. Applying Grease to Clutch Controls

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Supply from grease nipple (for contact surface with front Wheel bearing grease
retainer of clutch shifter) [NLGI No.2 (Li soap)]
(every 5,000 km)
– As required
or
Supply from grease nipple (for release fork shaft) ESSO UNIREX N3
(every 25,000 km)

CAUTION
• When filling the grease from the grease nipple, be careful not to overfill as it will cause clutch slippage.
• Be sure to use the specified grease with anti-seizing property. Never use the chassis grease or the like.

• The service interval may differ depending on the types of grease. Observe the service interval specified for the
grease to be used.

• Fill the grease to the release fork shafts and the contact surface
of the clutch shift and transmission through grease nipples. Note
that the grease nipples for the release fork shafts are on both
right and left sides.

21B-17
CLUTCH PEDAL

Removal sequence
1 Return spring 6 Pedal pad 10 Clutch master cylinder
2 Clevis pin 7 Clutch pedal (See later section.)
3 Collar 8 Fluid hose 11 Clutch switch
4 Bushing 9 Fluid pipe 12 Rubber stopper
5 Stopper 13 Clutch pedal bracket

Installation sequence
Follow the removal sequence in reverse.
• Perform inspection and adjustment of clutch pedal after installation.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
62 N
1 Return spring load (installed length: 124.2) 64 ± 1.0 N {6.5 ± 0.1 kgf} Replace
{6.3 kgf}
3, 4 Clearance between collar and bushing 0.02 to 0.26 0.4 Replace bushing

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (clutch pedal bracket mounting)
9 to 14 {0.9 to 1.4} –
Bolt (clutch pedal bracket mounting)

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Outer periphery of clevis pin Chassis grease
As required
Inner surface of bushing [NLGI No.1 (Li soap)]

21B-18
 21B
M E M O

21B-19
CLUTCH MASTER CYLINDER
Disassembly sequence
1 Push rod
2 Boot
3 Piston stop ring
4 Piston stop plate
5 Supply valve stopper
6 Piston
7 Return spring
8 Nipple
9 Nipple
10 Cylinder

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

Repair kit: Piston and boot kit

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
6, 10 Clearance between piston and cylinder 0.040 to 0.125 0.15 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Push rod (lock nut mounting) 9.8 to 15 {1.0 to 1.5} –
Supply valve stopper 1.5 to 2.9 {0.15 to 0.30} –
Nipple 25 to 34 {2.5 to 3.5} –
Nipple 69 to 78 {7 to 8} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Sliding surfaces between piston and cylinder
Rubber grease As required
Entire surface of piston cup packing

Removal procedure
Removal: Piston
• Close the opening of the nipple on the cylinder. Wrap the cylin-
der body with a shop towel or equivalent around the opening to
catch the piston.
• Feed compressed air gradually to remove the piston.
WARNING
• Do not apply compressed air suddenly at high pressure.
Otherwise, the piston will fly out with full force.

21B-20
 21B
Adjustment procedure
Adjustment: Push rod length
• Measure the distance from the head to the push rod end. If the
measurement is not 141 mm as illustrated, adjust by loosening
the lock nut and rotating the head.
• After adjustment, tighten the lock nut.

Installation procedure
Installation: Piston
• Apply grease to sliding surfaces of the piston and cylinder.
• Align the piston groove with the cylinder hole, and use the sup-
ply valve stopper as a detent.

21B-21
CLUTCH BOOSTER

Removal sequence
1 Fluid hose 6 Return spring 10 Clutch booster (See later sec-
2 Eyebolt 7 Clevis pin tion.)
3 Connector 8 Return spring claw 11 Bracket
4 Eyebolt 9 Push rod
5 Air pipe : Non-reusable parts

Installation sequence
Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Eyebolt 34.3 {3.5} –
Fluid hose 108 {11} –
Nut (push rod mounting) 42.2 {4.3} –
Bolt (clutch booster mounting) 20 to 25 {2.0 to 2.5} –
Eyebolt 35.3 {3.6} –

21B-22
 21B
Removal procedure
Removal: Fluid hose
• To remove the fluid hose, disconnect the connection with the
pipe on the frame before disconnecting the connection on the
clutch booster.
CAUTION
• After removing the fluid hose, plug up the pipe to prevent
clutch fluid from flowing out.

Installation procedure
Installation: Fluid hose
• To install the fluid hose, connect the connection with the pipe on
the clutch booster before connecting the connection on the
frame.

21B-23
CLUTCH BOOSTER
Clutch Booster

Disassembly sequence
1 Spring claw 16 Oil seal 32 Cup packing
2 Spacer 17 O-ring (air pressure side)
3 Push rod 18 O-ring 33 Relay piston
4 Guard 19 Bushing 34 Fitting
5 Retaining ring 20 Gasket 35 Exhaust cover
6 Washer 21 Connector 36 Air bleeder
7 Cup packing 22 Gasket 37 End plate
(fluid pressure side) 23 Spring 38 Spring
8 Cup packing 24 Poppet valve 39 Cup packing
(atmosphere side) 25 Upper valve body 40 Piston
9 Hydraulic piston 26 Spring 41 O-ring
10 Hydraulic cylinder 27 Diaphragm 42 Push rod
11 Retaining ring 28 Plate 43 Cylinder shell
12 Washer 29 Retaining ring
13 Retainer 30 Gasket : Non-reusable parts
14 Cup packing 31 Cup packing
15 Washer (fluid pressure side)

21B-24
 21B
Assembly sequence
Follow the disassembly sequence in reverse.

Repair kit: Clutch booster kit

CAUTION
• Be careful not to damage the peripheries of the relay piston and hydraulic piston because damaging them
causes defective operation of the clutch booster.
• Use the right types of oil and grease for the right locations. Otherwise, rubber parts are degraded and
swelled.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Clearance between hydraulic piston and hydraulic cylin-
9, 10 0.01 to 0.06 0.8 Replace
der
2.6 ± 0.26 N 2.3 N
23 Spring installed load (installed length 13) Replace
{0.27 ± 0.027 kgf} {0.23 kgf}
12.3 ± 1.23 N 10.4 N
26 Spring installed load (installed length 10) Replace
{1.25 ± 0.1 kgf} {1.06 kgf}
33, 34 Clearance between relay piston and fitting 0.04 to 0.08 0.11 Replace
88.3 ± 8.83 N 75 N
37 Spring installed load (installed length 59.9) Replace
{9.0 ± 0.9 kgf} {7.6 kgf}
40, 43 Clearance between piston and cylinder shell 0.20 to 0.75 1.5 Replace
42 Bend of push rod – 0.1 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Connector
19.6 to 29.4 {2.0 to 3.0} –
Nut (piston mounting)
Hydraulic cylinder 29.4 to 39.2 {3.0 to 4.0} –
Bolt (upper valve body mounting) 3.9 to 5.9 {0.4 to 0.6} –
Air bleeder 6.9 to 12.7 {0.7 to 1.3} –
Exhaust cover 9.8 to 49.0 {1.0 to 5.0} –
Bushing 7.8 to 9.8 {0.8 to 1.0} –
Fitting 14.7 to 24.5 {1.5 to 2.5} –
Nut (coupling between body, bracket and cylinder shell) 19.6 to 24.5 {2.0 to 2.5} –

21B-25
CLUTCH BOOSTER
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
O-ring
Entire surface of cup packing (piston) Air master paste As required
Inside circumference of cylinder shell
Entire surface of cup packing (hydraulic piston, relay pis-
ton, retainer)
Periphery of relay piston
O-ring (retainer)
Push rod sliding surface of guard
Rubber grease As required
Periphery of hydraulic piston
Fill in grease groove of hydraulic piston
Inside circumference of hydraulic cylinder
Tip of push rod
Inside circumference of fitting
Gasket Silicone Grease As required
Thread area of exhaust cover ThreeBond 1105 As required

Special tools
Mark Tool name and shape Part No. Application
Stand plate *910-10690 Fixation of clutch booster
L-Spanner *910-23260 Removal and installation of fitting
Fluid pressure side *910-24902
For relay piston
Air pressure side *910-24905
Cup insert guide Installation of cup packing
For hydraulic Fluid pressure side *910-23292
piston Atmosphere side *910-23293
Needle *910-21200 Removal of cup packing
Push-out tool *910-23100 Removal of oil seal
Insert tool *910-23090 Installation of oil seal
Push guide *910-23270 Centering diaphragm
*: Bosch No.

Work before removal

Alignment mark: Each joint
• Make an alignment mark on each joint of parts before disassem-
bly.
• Secure the end plate flange of the clutch booster to , and
hold it in a vise.

21B-26
 21B
Removal procedure
Removal: Cup packing
• Using , remove the cup packing from the hydraulic piston.

Removal: Oil seal

Removal: Fitting
• Using , remove the fitting from the end plate.

Removal: Cup packing

• Using , remove the cup packing and O-ring from the relay
piston.

Removal: Piston
• Hold the socket in a vise, and insert the hexagonal surface of the
push rod into the socket to remove the nut.

21B-27
CLUTCH BOOSTER
Cleaning procedure
Cleaning
• Clean the metal parts using metal cleaner.
• Use #800 or finer emery paper to remove rust, scoring, dents or
other damage from the metal parts. If these cannot be removed
with emery paper, replace the part. Resurfaced parts must be
checked for air or fluid leakage.
• Clean the rubber parts using a cloth moistened with alcohol.

Installation procedure
Installation: Spring, cup packing and piston
• Install the spring so that its convex faces upward.
• After tightening the nut, caulk it at two locations with a punch.
• After applying grease (air master paste) to its entire surface, in-
stall the cup packing to the piston ensuring that it faces correctly
as illustrated.

Installation: Cup packing, O-ring and relay piston

• Apply grease (rubber grease) to the inside circumference of the
cup packing on the air pressure side, and install it on the relay
piston in the illustrated direction, using .

• Apply grease (rubber grease) to the inside circumference of the

cup packing on the fluid pressure side, and install it on the relay
piston in the illustrated direction, using .

Installation: Fitting
• Using , installation the fitting from the end plate.

21B-28
 21B
Installation: Upper valve body
• Install upper valve body after centering diaphragm with .

Installation: Oil seal

Installation: Cup packing and hydraulic piston

• Apply grease (rubber grease) to the inside circumference of the
cup packing on the atmospheric side, and install it on the hy-
draulic piston in the illustrated direction, using .

• Apply grease (rubber grease) to the inside circumference of the

cup packing on the fluid pressure side, and install it on the hy-
draulic piston in the illustrated direction, using .
• Fill the grease groove of the hydraulic piston with grease (rubber
grease).

Installation: Retaining ring

• Fit retaining ring in hydraulic cylinder in the direction shown so
that ring ends is in the horizontal direction.

21B-29
CLUTCH PROPER

Removal sequence
1 Pressure plate and lever (See later section.) 7 Intermediate plate
2 Rear clutch disc 8 Flywheel ring
3 Strap bolt 9 Front clutch disc
4 Washer
5 Strap plate : Locating pin
6 Stopper

WARNING
• The pressure plate and lever, intermediate plate and flywheel ring is heavy (approx. 70 kg). Handle it with
care.

Installation sequence
Follow the removal sequence in reverse.

CAUTION
• Use care not to allow oil and grease on the surface of the clutch disc, because it can cause the clutch to
slip.

21B-30
 21B
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Lateral runout 0 to1.0 – Replace
Vertical runout 0 to1.0 – Replace
2, 9 Clutch disc
Play in revolving direction in splines 0.06 to 0.20 0.42 Replace
Depth from facing surface to rivet 1.7 to 2.3 0.2 Replace
Interference between strap bolt and bolt hole in strap
3, 5 0.013 to 0.135 0.3 Replace
plate
Thickness 28.9 to 29.1 27.1 Replace
Intermedi-
7 Flatness 0.1 or less 0.2 Replace
ate plate
Diameter of strap bolt fitting hole 10.2 to 10.3 10.5 Replace
8 Diameter of strap bolt fitting hole in flywheel ring 10.2 to 10.3 10.5 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (pressure plate and lever mounting) 57 {5.8} –
Bolt (pressure plate and lever mounting)
74 {7.56} –
Bolt (intermediate plate mounting)
Strap bolt (strap plate mounting) 49.0 to 58.8 {5.0 to 6.0} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Entire surface of spline Molybdenum disulfide grease 2.2 to 3.2 g
Filled in grease grooves of splines [NLGI No.2 (Li soap)] 5.4 to 7.1 g

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Clutch alignment
arbor

A B C D MH061600 Holding clutch disc

φ48 φ30 140 300

Stopper bolt
Removal and installation of pressure
A B C 43502-39100
plate and lever (4 bolts to be used)
55 30 M10×1.25

Washer
Removal and installation of pressure
A B 43502-39200 plate and lever (4 washers to be
used)
φ24 φ12.5

21B-31
CLUTCH PROPER
Mark Tool name and shape Part No. Application

Clutch lever aligner

Adjustment of release lever plate
A MH061794
height
34 ± 0.5

Removal procedure
Removal: Pressure plate and lever
• Insert into the pilot bearing of the flywheel to support the
clutch disc.
• Push and compress the diaphragm spring securing 4 locations
with and .
CAUTION
• Never attempt to remove bolts without using and ,
otherwise, the pressure plate and lever will be pushed up by
the force of the pressure spring, damaging the strap plate
behind it, and the assembly will also fall off the flywheel lo-
cating pins.

Inspection procedure
Inspection: Clutch disc
(1) Depth from facing surface to rivet
• If the measured value is equal to or less than the limit, replace
the clutch disc.

(2) Play in revolving direction in splines

• Reshape a feeler gauge such that it can be inserted into the
drive pinion splines. Then, using the gauge, measure the splines
for play in revolving direction.
• If the measured value is equal to or exceeds the limit, replace
the clutch disc.

21B-32
 21B
Inspection: Intermediate plate
(1) Thickness
• Measure the thickness of the intermediate plate at the friction
surface in the following procedure. If the measured value is less
than the specified limit, replace the intermediate plate.
• Measure the standard dimension (area the clutch disc does not
contact).

• Measure the clearance between the friction surface (within the il-
lustrated range) and the standard dimension, and deduct this
value from the standard dimension. This value is the thickness
of the intermediate plate.

Outside diameter 400 mm

Inside diameter 250 mm

(2) Flatness
• Measure the clearance between the intermediate plate and
straight edge. (Consider the intermediate plate as a plane.)
• If the measured value exceeds the specified limit, correct or re-
place the intermediate plate.

(3) Inside diameter of strap bolt fitting hole

• If the measured value exceeds the specified limit, replace the in-
termediate plate.

Inspection: Flywheel ring

• Measure the bore diameter of the strap bolt fitting holes in the
flywheel ring.
• If the measurement exceeds the limit, replace the flywheel ring.

21B-33
CLUTCH PROPER
Installation procedure
Installation: Clutch disc
• Install the clutch discs ensuring that the letter marks on the discs
face the correct directions.

Installation: Stopper
• When intermediate plate has been corrected by grinding or re-
placed, install stopper to achieve the specified dimension of 21 ±
1 mm between the flywheel and the intermediate plate.

Installation: Pressure plate and lever

• Install the pressure plate and lever by following the removal pro-
cedure in reverse.
(See “ Removal: Pressure plate and lever”.)
• Tighten the bolts diagonally and gradually to the specified
torque.
CAUTION
• After installation, be sure to remove and (4 loca-
tions). If they are left installed, the clutch cannot be en-
gaged.

• Using , check pressure plate and lever for clutch cover to

release lever plate height.
CAUTION
• Perform this height inspection only when clutch discs are
new.
• Do not attempt to adjust the release lever plate height for
new pressure plate and lever. Their release lever plate
height has been correctly adjusted before shipment.

• Adjust, if required, the release lever plate height by turning sup-

port nut with lock bolt and lock plate detached.

21B-34
 21B
• Make certain that the clearance between release lever and re-
lease lever plate is such that a 0.05 mm feeler gauge cannot be
inserted between them.
• If there is excessive clearance, press the release lever plate in
strongly using your fingers, and return it slowly to lessen the
clearance.

21B-35
CLUTCH PROPER
Pressure Plate and Lever

Disassembly sequence
1 Strap bolt 8 Pressure spring 15 Bushing
2 Washer 9 Pressure spring seat 16 Bushing
3 Lock bolt 10 Lever support pin 17 Release lever
4 Lock plate 11 Return spring 18 Pressure plate
5 Support nut 12 Release lever plate
6
7
Clutch cover
Pressure spring seat
13
14
Lever support
Release lever pin
*a:: Strap plate
Non-reusable parts

• Do not remove the bushing unless any abnormality is found.

Assembly sequence
Follow the disassembly sequence in reverse.

Repair kit: Clutch release lever kit

21B-36
 21B
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Clearance between strap bolt and strap plate of clutch
*
1, a
cover
0.004 to 0.116 0.3 Replace

Installed load (installed length 950 N

1130 N {115.7 kgf}
8 Pressure spring 71.5) {97 kgf} Replace
Slant 0 to 3.9 5.9
10, 15 Clearance between lever support pin and bushing 0.02 to 0.11 0.4 Replace
Difference
between
12 Height of release lever plate 80.6 ± 0.5 Adjust
any two: 0.5
or less
14, 16 Clearance between release lever pin and bushing 0.02 to 0.11 0.4 Replace
Thickness 62.0 ± 0.1 56.8 Replace
Correct or
Flatness 0 to 0.05 0.2
18 Pressure plate replace
Inside diameter of fitting hole +0.024
12.2 +0.006 12.5 Replace
of strap bolt

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Strap bolt (strap plate mounting) 39 to 49 {4 to 5} –
Lock bolt 9.8 to 14.7 {1.0 to 1.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Threaded and spherical surfaces of support nut Anti-seizure compound As required
Sliding surface of support nut and clutch cover
Sliding surface of lever support and release lever Molybdenum disulfide grease
As required
Sliding surface of release lever and pressure plate [NLGI No.2 (Li soap)]
Sliding surface of release lever plate and release lever

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Stopper bolt

A B C 43502-39100
55 30 M10×1.25

Removal and installation of pressure

plate and lever (4 bolts to be used)

Washer

A B 43502-39200
φ24 φ12.5

Removal and installation of clutch

Clutch installer MH061331
cover

21B-37
CLUTCH PROPER
Mark Tool name and shape Part No. Application

Clutch lever aligner

A MH061794 Adjustment of release lever heights

34 ± 0.5

Work before removal

Alignment mark: Pressure plate and lever
• Make an alignment mark on each joint of parts before disassem-
bly.
Removal procedure
Removal: Clutch cover
• Remove the strap bolt, washer, lock bolt, lock plate and support
nut while pushing and compressing the pressure spring securing
4 locations with and .

• Remove and using with the pressure spring

pushed and compressed.
• Gradually loosen and remove the clutch cover after the
pressure spring becomes ineffective.

21B-38
 21B
Inspection procedure
Inspection: Clearance between strap bolt and strap plate of
clutch cover
• If the measured value exceeds the specified limit, replace faulty
parts.

Inspection: Clearance between lever support pin and bush-

ing
• If the measured value exceeds the specified limit, replace the
bushing.

Inspection: Clearance between release lever pin and bush-

ing
• If the measured value exceeds the specified limit, replace the
bushing.

Inspection: Pressure plate

(1) Thickness
• Measure the thickness of the pressure plate at the friction sur-
face in the following procedure. If the measured value is less
than the specified limit, replace the pressure plate.
• Measure the standard dimension (area the clutch disc does not
contact).

• Measure the clearance between the friction surface (within the il-
lustrated range) and the standard dimension, and deduct this
value from the standard dimension. This value is the thickness
of the pressure plate.

Outside diameter 400 mm

Inside diameter 250 mm

21B-39
CLUTCH PROPER
(2) Flatness
• Measure the clearance between the pressure plate and straight
edge. (Consider the pressure plate as a plane.)
• If the measured value exceeds the specified limit, correct or re-
place the pressure plate.

(3) Inside diameter of strap bolt fitting hole

• If the measured value exceeds the specified limit, replace the
pressure plate.

Installation procedure
Installation: Pressure spring
• If the pressure plate is corrected, assemble between the pres-
sure plate and pressure spring a washer for adjustment equiva-
lent to the correction amount.

Correction amount Type and number of washers

Less than 1 mm Not necessary
Between 1 mm and less
One washer of 1.2 mm
than 2 mm
Between 2 mm and less Two washers of 1.2 mm or one washer of
than 3 mm 2.3 mm

Installation: Clutch cover

• To install, follow the removal sequence in reverse.
(See “ Removal: Clutch cover”.)
Work after installation
Adjustment: Height of release lever
• Using , compress pressure spring and adjust with support nut the
release lever plate height from the friction surface of intermediate plate
for the standard value. Then temporarily tighten lock bolt.

21B-40
 21B
• Make certain that the clearance between release lever and re-
lease lever plate is such that a 0.05 mm feeler gauge cannot be
inserted between them.
• If there is excessive clearance, press the release lever plate in
strongly using your fingers, and return it slowly to lessen the
clearance.

21B-41
CLUTCH CONTROL

Disassembly sequence
1 Grease nipple 5 Release bearing 9 Release fork shaft
2 Flexible hose 6 Clutch shifter 10 Key
3 Return spring 7 Set screw 11 Release fork
4 Elbow 8 Grease nipple 12 Clutch housing

Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION
• When supplying grease from the grease nipple, do not supply too much to prevent clutch slippage.
• To prevent seizure, only use the specified grease.
• When inserting the release fork shaft into the release fork, take care not to smear the fitting hole with
grease. Grease in the fitting hole can cause the released fork to be damaged.
• Be sure to use the specified grease with anti-seizing property. Never use the chassis grease or the like.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Set screw 53.9 {5.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Clutch shifter contact face with release fork Wheel bearing grease
[NLGI No.2 (Li soap)] or As required
Supply from grease nipple ESSO UNIREX N3

21B-42