GROUP 21A CLUTCH

<C12W43P>

SPECIFICATIONS ........................................................................... 21A-2

STRUCTURE AND OPERATION

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

TROUBLESHOOTING .................................................................... 21A-8

ON-VEHICLE INSPECTION AND ADJUSTMENT

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

CLUTCH PEDAL ........................................................................... 21A-18

CLUTCH MASTER CYLINDER .................................................... 21A-20

CLUTCH BOOSTER ..................................................................... 21A-22

CLUTCH PROPER .........................................................................21A-30

CLUTCH CONTROL ..................................................................... 21A-34

21A-1
SPECIFICATIONS / STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Model C12W43P
Clutch model
Type Pull type
Drive type Strap drive
Clutch disc Model Dry, single 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.

21A-2
 21A
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.

21A-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.

21A-4
 21A
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.

21A-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

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

4.2 When clutch pedal is pressed

• Hydraulic 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 bear-
ing and diaphragm 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
the engine power is therefore not
transmitted to the transmission.

21A-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
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 Gr22A
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

21A-8
 21A
M E M O

21A-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.

21A-10
 21A
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

21A-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.

21A-12
 21A
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

21A-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 175 ± 5 – Replace
– Clutch master cylinder push rod play (clutch pedal play) 2.5 (15 ± 2) – Adjust or replace
– Clutch booster push rod play 4.8 – Adjust or replace
Clutch pedal play
– (clutch master cylinder push rod play and clutch boost- 46 to 58 – 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} –

21A-14
 21A
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.

21A-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.

21A-16
 21A
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 needle roller bearing) 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 needle roller bearings and the contact sur-
face of the clutch shifter and front retainer through grease nip-
ples. Note that the grease nipples for the needle roller bearings
are on both right and left sides.

21A-17
CLUTCH PEDAL

Removal sequence
1 Clutch switch 8 Pedal pad 14 Rubber stopper
2 Switch bracket 9 Clutch pedal 15 Clutch pedal bracket
3 Return spring 10 Fluid hose
4 Clevis pin 11 Fluid pipe : Non-reusable parts
5 Collar 12 Clutch master cylinder
6 Bushing (See later section.)
7 Stopper 13 Clutch switch

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
3 Return spring load (installed length: 124.2) 64 ± 1.0 N {6.5 ± 0.1 kgf} Replace
{6.3 kgf}
5, 6 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)]

21A-18
 21A
M E M O

21A-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.

21A-20
 21A
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.

21A-21
CLUTCH BOOSTER

Removal sequence
1 Fluid hose 7 Clevis pin 13 Connector
2 Eyebolt 8 Clevis 14 Clutch booster (See later sec-
3 Connector 9 Return spring claw tion.)
4 Air hose 10 Push rod
5 Air hose 11 Eyebolt : Non-reusable parts
6 Return spring 12 Air pipe

Installation sequence
Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Eyebolt 27 to 42 {2.7 to 4.3} –
Air hose 40.2 to 44.1 {4.1 to 4.5} –
Air hose 182 {18.6} –
Bolt (clutch booster mounting) 40.2 {4.1} –
Air pipe 60 {6.1} –
Eyebolt 35.3 {3.6} –
Nut (connector mounting) 202 {21} –
Nut (clevis mounting) 42.2 {4.3} –
Nut (return spring claw mounting) 70.3 {7.2} –

21A-22
 21A
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: Return spring
• Install the return spring in the illustrated direction.

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.

21A-23
CLUTCH BOOSTER
Clutch Booster

Disassembly sequence
1 Bracket 18 Cup packing 31 Hydraulic piston
2 Bracket (fluid pressure side) 32 O-ring
3 Bracket 19 Cup packing 33 Exhaust cover
4 Bracket (air pressure side) 34 Air bleeder
5 Guard 20 O-ring 35 Body
6 Spring pin 21 Relay piston 36 Spring
7 Retaining ring 22 Retaining ring 37 Spring
8 O-ring 23 Washer 38 Cup packing
9 Guide 24 O-ring 39 Piston plate
10 Spring 25 Retainer 40 O-ring
11 O-ring 26 Cup packing 41 Push rod
12 Retainer valve 27 Retainer 42 O-ring
13 Intake valve 28 Wear ring 43 Collar
14 Upper valve body 29 Cup packing 44 Cylinder shell
15 Plug (fluid pressure side)
16 O-ring 30 Cup packing : Non-reusable parts
17 Spring (atmosphere side)

21A-24
 21A
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
45 N
10 Spring installed load (installed length 11.1) 49 ± 4.9 N {5 ± 0.5 kgf} Replace
{4.6 kgf}
34 N
17 Spring installed load (installed length 13.1) 38 ± 3.8 N {3.9 ± 0.4 kgf} Replace
{3.5 kgf}
Clearance between relay pis- Relay piston 0.04 to 0.09 0.11
21, 24 Replace
ton and body Valve piston 0.1 to 0.25 0.3
31, 35 Clearance between hydraulic piston and body 0.01 to 0.06 0.8 Replace
118 ± 11.8 N 58 N
36 Spring installed load (installed length 59.5) Replace
{12 ± 1.2 kgf} {5.9 kgf}
39, 44 Clearance between piston plate and cylinder shell 0.20 to 0.75 1.5 Replace
41 Bend of push rod – 0.15 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (bracket mounting)
19.6 to 29.4 {2 to 3} –
Nut (coupling between body, bracket and cylinder shell)
Nut (piston plate mounting) 3.9 to 4.9 {0.4 to 0.5} –
Bolt (upper valve body mounting) 3.9 to 5.9 {0.4 to 0.6} –
Air bleeder 6.9 to 13 {0.7 to 1.3} –
Exhaust cover 14.7 to 19.6 {1.5 to 2.0} –
Plug 9.8 to 20 {1 to 2} –

21A-25
CLUTCH BOOSTER
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Fill in O-ring groove of guide
O-ring
Entire surface of cup packing (piston plate)
Inside circumference of cylinder shell Air master paste As required
Guide sliding surface of intake valve
Fill in O-ring groove of intake valve
Guide sliding surface of upper valve body
Entire surface of cup packing (hydraulic piston, relay pis-
ton, retainer)
Periphery of relay piston of φ16 mm
O-ring (retainer)
Push rod sliding surface of retainer Rubber grease As required
Periphery of hydraulic piston
Fill in grease groove of hydraulic piston
Inside circumference of bodies of φ16 mm and φ19.8 mm
Tip of push rod
O-ring (relay piston)
Periphery of relay piston φ20 mm
Silicon Grease As required
Fill in O-ring groove of relay piston φ20 mm
Inside circumference of body of φ20 mm
Thread area of exhaust cover ThreeBond 1105 As required
Thread of plug ThreeBond 1213 As required

Special tools
Mark Tool name and shape Part No. Application
Stand plate *910-10692 Fixation of clutch booster
Pliers *910-21471 Removal of relay piston
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 and O-ring
*: Bosch No.

Work before removal

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

21A-26
 21A
Removal procedure
Removal: Relay piston
• Using , remove the relay piston from the body.

Removal: Cup packing and O-ring

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

Removal: O-ring
• Using , remove the O-ring from the retainer.

Removal: Cup packing

• Using , remove the cup packing from the hydraulic piston.

Removal: Piston plate

• Hold the socket (21 mm) in a vise, and insert the hexagonal sur-
face of the push rod into the socket to remove the nut.

21A-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 plate
• 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 plate ensuring that it faces
correctly as illustrated.

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, washer, O-ring, retainer, cup

packing and retainer
• Install the retainer, cup packing, retainer, O-ring, washer and re-
taining ring on the body in the illustrated direction.
• Apply grease (rubber grease) to the O-ring and cup packing be-
fore they are installed.

21A-28
 21A
Installation: Cup packing, O-ring and relay piston
• Apply grease (Shin-Etsu Chemical Silicon Grease FG721) to the
O-ring and install it on the relay piston.
• Fill the O-ring groove of the relay piston with grease (Shin-Etsu
Chemical Silicon Grease FG721).
• 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 .

21A-29
CLUTCH PROPER

Removal sequence
1 Snap ring 5 Support plate : Locating pin
2 Release lever plate 6 Cone spring
3 Connector 7 Clutch cover
4 Release bearing 8 Clutch disc

CAUTION
• The pressure plate and lever is heavy (approx. 40 kg). Handle it with care.
• Clutch cover consists of pressure plate, strap plate, diaphragm spring, etc., and these parts are held to-
gether as one-piece unit by riveting. If any of them becomes faulty, therefore, the whole clutch cover must
be replaced.

Installation sequence
Follow the removal sequence in reverse.

CAUTION
• To prevent slippage of the clutch disc, do not smear the surface of the clutch disc with grease or oil.

21A-30
 21A
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Peripheral elevation of pressure plate 0 to 0.05 – Repair or replace
Clutch
7 Clearance between diaphragm spring and
cover 0 to 1.2 – Replace
wiring
Radial run-out 0 to 1.0 – Replace
Axial run-out 0 to 1.5 – Replace
8 Clutch disc
Play in rotating direction in spline 0.06 to 195 0.42 Replace
Depth from facing surface to rivet 2.2 to 2.8 0.2 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (clutch cover mounting) 65 to 85 {6.6 to 8.7} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Entire surface of spline Molybdenum disulfide grease 3.3 to 4.7 g
Filled in grease grooves of splines [NLGI No.2 (Li soap)] 8.1 to 10.9 g
Threads of connector Loctite 272 As required

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Clutch alignment
arbor

A B C MH061389 Holding clutch disc

φ39.5 φ30 90

Set plate
Removal and installation of clutch
A ME551279
cover set (four pcs needed)
2.9

Removal: Clutch cover

• Insert into flywheel pilot bearing to support clutch disc.
• Fit (four) to bolts B (four places) of clutch cover to hold dia-
phragm spring, then remove bolt A. Hold with gummed
cloth tape so that the plates will not come off the clutch cover.
CAUTION
• If bolts (four places) are removed without using , clutch
cover will pop up by the force of diaphragm spring, and this
will damage the strap plate. The clutch cover will then drop
out of the flywheel locating pins.

21A-31
CLUTCH PROPER
Inspection procedure
Inspection: Clutch cover
(1) Peripheral elevation of pressure plate
• Place a straight edge across the friction surface of the pressure
plate. Using a feeler gauge, measure the clearance between
them at 4 positions identified by arrows in the illustration.
• Calculate the peripheral elevation by subtracting the clearance B
at the peripheral section from the clearance A at the center sec-
tion.
• If the peripheral elevation is out of the standard value, replace
the clutch cover.

(2) Inspection of diaphragm spring

• Put the clutch cover on a horizontal place, inspect the dia-
phragm spring for play by moving the end of inside diaphragm
spring as illustrated.
• If the spring has play, the clutch cover needs to be replaced.

Inspection: Clutch disc

(1) Depth from facing surface to rivet
• Measure depth from the clutch disc facing surface to the 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.

21A-32
 21A
Installation procedure
Installation: Clutch disc
• Install the clutch disc so that its Part No. can be seen.

Installation: Clutch cover

• Install the clutch cover by following the removal procedure in re-
verse.
(See “ Removal: Clutch cover”.)
• Tighten the bolts diagonally and gradually to the specified
torque.
• After tightening, remove and .
CAUTION
• Leave taped to clutch cover. Otherwise, they may
come off and get into the clutch cover while tightening
bolts.
• After installation, be sure to remove (4 locations). If
they are left installed, the clutch cannot be engaged.

21A-33
CLUTCH CONTROL

Disassembly sequence
1 Set screw 6 Release fork 11 Flexible hose
2 Grease nipple 7 Clip 12 Needle roller bearing
3 Release fork shaft 8 Bracket 13 Clutch housing
4 Key 9 Grease nipple
5 Cam follower 10 Connector : Non-reusable parts

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.

21A-34
 21A
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Flexible hose (connection to connector) 12 to 16 {1.2 to 1.6} –
Set screw 9 to 13 {0.9 to 1.3} –
Bolt (flexible hose mounting) 9.8 to 14.7 {1.0 to 1.5} –
Bolt (flexible hose mounting) 4 to 6 {0.4 to 0.6} –
Bolt (flexible hose mounting) 4.71 {0.5} –

Lubricant and/or sealant

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

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Needle roller
bearing installer
44590-12600 Installation of needle roller bearing
A B C
φ37 φ30 43

Installation procedure
Installation: Needle roller bearing
• Install the needle roller bearing with the red seal-fitted side out-
ward. Use so that it is installed as specified without fail.
The distance from the clutch housing end face to the needle
bearing end face must be in accord with the dimension shown in
the illustration.
CAUTION
• To prevent damage, do not strike the needle roller bearing
directly with a hammer when installing it.

21A-35
CLUTCH CONTROL
Installation: Flexible hose
• To clamp flexible hose, fit clip in such a way that it may roughly
cover the clamping portion paint-marked on the hose and may
be positioned at an illustrated angle with respect to bracket.

Installation: Cam follower

• To install cam follower, prepare jig by which shaft of the cam fol-
lower can be directly driven into position without causing any
damage to boss and outer race.
• Press-fit cam follower into release fork by using jig and bar.

Installation: Key
• Install the key on the release fork shaft in the illustrated direc-
tion.
• The key must be installed in the key groove in the release fork
shaft such that it bottoms out and that it is centered in the
groove.

21A-36