Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 1608
7C–8
CLUTCH
Clutch Assembly (Y22SE)
Clutch Assembly (Y22SE) and Associated Parts
201RX003
Legend
(1) Transmission Assembly
(2) Pressure Plate Assembly
(3) Driven Plate Assembly
(4) Release Bearing
(5) Shift Fork
(6) Crank Shaft Bearing
Removal
1. Remove transmission assembly, refer to “MANUAL
TRANSMISSION” of Section 7B for “REMOVAL AND
INSTALLATION” procedure.
CLUTCH
7C–9
2. Use the clutch pilot aligner (7) J–42877 to prevent the
driven plate assembly from falling free.
201RX002
Legend
(3) Driven Plate Assembly
(2) Pressure Plate Assembly
(7) Pilot Aligner
3. Mark the flywheel, clutch cover and pressure plate (2)
lug for alignment when installing.
4. Loosen the clutch cover bolts in the numerical order
shown in the illustration.
201RS036
5. Remove pressure plate assembly (2) and driven plate
assembly (3).
6. Remove release bearing (4).
NOTE: The release bearing is permanently packed with
lubricant and should not be soaked in cleaning solvent, as
this will dissolve the lubricant.
7. Remove shift fork.
D
Do not remove crank shaft bearing (6) except for
replacement.
Remove the crank shaft bearing (6) using remover
J–5822 and sliding hammer J–23907.
015RS077
Inspection and Repair
Make necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.
Pressure Plate Assembly
Visually inspect the pressure plate friction surface for
excessive wear and heat cracks. If excessive wear or
deep heat cracks are present, the pressure plate must be
replaced.
7C–10
CLUTCH
Pressure Plate Warpage
Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
201RS038
If any of the measured values exceed the specified limit,
the pressure plate must be replaced.
Pressure Plate Warpage
Limit: 0.3mm (0.012in)
Clutch Cover
Visually inspect the entire clutch cover for excessive
wear, cracking, and other damage. The clutch cover must
be replaced if any of these conditions are present.
201RS039
Clutch Set Force
1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure plate. A
metal sheet with thickness of 7.0mm (0.276in) may
be used in place of the driven plate.
3. Compress the pressure plate assembly until the
distance becomes 4mm (0.157in).
4. Note the pressure gauge reading.
Clutch Set Force
Standard: 5488N (1235lb)
201RY00003
Diaphragm Spring Finger Height
1. Place a 7.0mm (0.276in) spacer beneath the
pressure plate.
2. Fully compress the pressure plate and diaphragm
spring.
There are two ways to do this:
a. Use a bench press to press down on the assembly
from the top.
b. Tighten the fixing bolts.
CLUTCH
7C–11
3. Measure the spring finger height from base to spring
tip.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Spring Finger Height
Standard: 37.5 mm – 39.5 mm (1.48 in – 1.56 in)
201RY00001
Shift Fork
1. Visually inspect the surfaces of the shift fork making
contact with the shift block.
2. Remove any minor stepping or abrasion from the shift
block with an oil stone.
3. Apply molybdenum disulfide type grease to the areas
as shown in the figure.
F07RW030
Driven Plate Assembly
1. Visually inspect the torsion spring for looseness,
breakage, and weakening. If any of these conditions
are discovered, the driven plate assembly must be
replaced.
2. Visually inspect the facing surfaces for cracking and
excessive scorching. Visually inspect the facing
surfaces for the presence of oil or grease. If any of
these conditions are discovered, the facing must be
cleaned or replaced.
201RS007
3. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be
removed with an oil stone.
Driven Plate Warpage
1. Insert the clutch pilot aligner J–42877 into the driven
plate splined hub.
The clutch pilot aligner must be held perfectly
horizontal.
2. Set a dial indicator to the driven plate outside
circumference.
201RS008
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