Isuzu N-Series. Service manual — part 867
CLUTCH 7C-17
Clutch Booster
Components
Removal
Before disassembling, mark the front shell and rear shell
for alignment.
1. Remove the clevis master cylinder push rod.
2. Remove the nut.
3. Remove the boots.
4. Remove the separator air cleaner.
5. Remove the body assembly booster No. 2 (rear
shell).
Legend
1. Clevis master cylinder push rod
10. Piston sub assembly booster
2. Nut
11. Disk reaction
3. Boots
12. Rod sub assembly booster piston
4. Separator air cleaner
13. Retainer rod
5. Seal booster body No. 2
14. Spring booster piston return
6. Body assembly booster No. 2
15. Body assembly booster No. 1
7. Diaphragm booster
16. Seal booster body No. 1
8. Key valve stopper
17. Ring circular
9. Valve sub assembly booster air
N7A0507E
7C-18 CLUTCH
• Separate the rear shell from the front shell us-
ing handle 9-8523-1733-0 and support plate 5-
8840-2056-0.
Caution:
Make sure to prevent the diaphragm spring from jump-
ing out.
6. Remove the body assembly booster No. 1 (front
shell).
7. Remove the spring booster piston return.
8. Remove the retainer rod.
9. Remove the rod sub assembly booster piston.
10. Remove the disk reaction.
11. Remove the diaphragm booster.
12. Remove the key valve stopper.
13. Remove the valve sub assembly booster air.
14. Remove the piston sub assembly booster.
15. Remove the link circular.
16. Remove the seal booster body No. 2.
17. Remove the seal booster body No. 1.
Inspection
Inspect the parts by washing and drying. Replace the
damaged parts with new ones.
Caution:
Use trichlene or metachlene (commercial product) for
metal parts, and clean alcohol for rubber and resin parts,
respectively.
Installation
Apply silicone grease to each sliding part.
• Seal mating part and lip part of the rear shell
• Internal & external surface of the diaphragm plate,
and outer circumference of the valve body
• Seal of the front shell, sliding surface of the push
rod and outer circumference of the valve booster
control
1. Install seal booster body No. 1.
2. Install body assembly booster No. 2.
3. Install the piston sub assembly booster.
4. Install the valve sub assembly booster air.
5. Install the key valve stopper.
6. Install the diaphragm booster.
Caution:
Never tear the diaphragm. Make sure that the reaction
disk is securely inserted to the surface B. (Bleed the air
from the outer circumference.)
7. Install the disk reaction (10).
8. Install the rod sub assembly booster piston (9).
9. Install the retainer rod.
10. Install the spring booster piston return.
11. Install seal booster body No. 1.
12. Install the link circular.
13. Install body assembly booster No. 1 (front shell).
• Installation has to be done using handle 9-
8523-1733-0 and support plate 5-8840-2056-0.
• When installing, the marks on the rear shell and
the front shell, which were put when disassem-
bling, has to mate with each other.
N7A0508E
N7A0509E
CLUTCH 7C-19
14. Install the separator air cleaner.
15. Install the boots.
16. Install the nut.
17. Install and adjust the clevis master cylinder push
rod.
• Adjust the distance between the center of the
pin hole of the clevis yoke and the installation
surface, and tighten the lock nut.
Dimension between the center of the pin hole of the cle-
vis yoke and the rear shell.
156.5 — 157.5 mm (6.161 — 6.201 in)
Tighten:
Lock nut to 26 N
⋅m (2.6 kg⋅m / 19 lb⋅ft)
Adjustment of the rod sub assembly booster piston
• After assembling the clutch booster, adjust the
length between the top of the push rod and the sur-
face of the rear shell.
Dimension between the top of the push rod and the rear
shell
3.75 — 4.0 mm (0.15 — 0.16 in)
N7A0508E
N7A0503E
N7A0510E
7C-20 CLUTCH
Slave Cylinder
Components
Removal
1. Remove the push rod (1).
2. Remove the boots (2).
3. Remove the piston assembly (3).
4. Remove the bleeder screw (5)
5. Remove the cylinder (4).
Inspection
Inspect the removed parts by washing. Replace the
damaged parts with new ones.
Cylinder body
• Check the fluid return port for clogging.
Internal parts
• Replace the parts indicated in the figure with new
ones.
Clearance between the cylinder body and the piston
Legend
1. Push rod
4. Cylinder body
2. Boots
5. Bleeder screw
3. Piston assembly
N7A0511E
N7A0512E
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