Isuzu N-Series. Service manual — part 827
7C-10 CLUTCH
3. Release Bearing Assembly
4. Driven Plate Assembly
• Apply multi-purpose with MOS
2
type grease to
the driven plate hub spline.
• Use the pilot aligner to install the driven plate
assembly.
Pilot Aligner: 5-8525-3001-0
5. Pressure Plate Assembly
• Tighten pressure plate assembly fixing bolts in
numerical order.
Tighten:
Pressure plate fixing bolt to 18 N
⋅m (1.8 kg⋅m / 13 lb⋅ft)
• Remove the pilot aligner.
Notice:
In case a new pressure plate assembly is mounted, after
tightening a pressure plate to the specified torque, be
sure to remove the wire for protection of a diaphragm
spring.
6. Transmission Assembly
Refer to “SECTION 7B ON-VEHICLE SERVICE:
TRANSMISSION ASSEMBLY REPLACEMENT”
in this manual.
Tighten:
Clutch housing to flywheel housing bolts to
• M10: 46 N
⋅m (4.7 kg⋅m / 34 lb⋅ft)
• M12: 91 N
⋅m (9.3 kg⋅m / 67 lb⋅ft)
Tighten:
Engine rear mounting nuts and bolts to
• M10: 40 N
⋅m (4.1 kg⋅m / 30 lb⋅ft)
• M12: 69 N
⋅m (7.0 kg⋅m / 51 lb⋅ft)
Tighten:
Front exhaust pipe bolts to 37 N
⋅m (3.8 kg⋅m / 27 lb⋅ft)
Tighten:
Exhaust brake bolts to 17 N
⋅m (1.7 kg⋅m / 12 lb⋅ft)
Tighten:
Slave cylinder bolts to 16 N
⋅m (1.6 kg⋅m / 12 lb⋅ft)
Perform slave cylinder adjustment before installa-
tion of the return spring.
1) Loosen the lock nut of the push rod.
2) Turn the adjust nut until it reaches the shift fork.
3) Back off the adjust nut 1.5 turns (shift fork free
play Approximately 2 mm/0.1 in).
4) Tighten the lock nut.
Tighten:
Push rod lock nut to 19 N
⋅m (1.9 kg⋅m / 14 lb⋅ft)
Wiring Connector Color
Back-up Light Switch: Brown
Neutral Switch: Gray
Tighten:
Propeller shaft nuts to 66 N
⋅m (6.7 kg⋅m / 48 lb⋅ft)
Legend
1. Shift fork
2. Support bolt
N7A0210E
N7A0211E
CLUTCH 7C-11
Clutch Control
Preparation
1. Meter Cluster
• Pull out the meter cluster and disconnect the
harness connectors.
2. Meter Assembly
• Remove the 5 fixing screws, then remove the
meter assembly and disconnect the harness
connector.
Removal
• Drain the clutch fluid from the clutch hydraulic
line.
Caution:
Do not let clutch fluid remain on a painted surface. Wash
it off immediately.
1. Clutch Pipe and Hose
2. Clutch Pedal and Bracket Assembly
3. Clutch Switch or Stopper Bolt
4. Shaft
Legend
1. Clutch pipe and hose
6. Return spring
2. Clutch pedal and bracket assembly
7. Clutch pedal
3. Clutch switch or stopper bolt
8. Master cylinder
4. Shaft
9. Flexible hose
5. Clevis pin
10. Slave cylinder
N7A0228E
7C-12 CLUTCH
5. Clevis Pin
6. Return Spring
7. Clutch Pedal
8. Master Cylinder
9. Flexible Hose
10. Slave Cylinder
Inspection and Repair
Make the necessary adjustment, repairs, and part re-
placement if excessive wear or damage is discovered
during inspection.
Installation
1. Slave Cylinder
Tighten:
Slave cylinder bolt to 19 N
⋅m (1.9 kg⋅m / 14 lb⋅ft)
• Perform slave cylinder adjustment before in-
stallation of the return spring.
1) Loosen the lock nut of the push rod.
2) Turn the adjust nut until it reaches the shift fork.
3) Back off the adjust nut 1.5 turns. (shift fork free
play approximately 2 mm/0.1 in).
4) Tighten the lock nut.
Tighten:
Push rod lock nut to 16 N
⋅m (1.6 kg⋅m / 12 lb⋅ft)
2. Flexible Hose
3. Master Cylinder
• Install the master cylinder assembly to the
clutch pedal bracket.
Tighten:
Fixing nuts to 13 N
⋅m (1.3 kg⋅m / 113 lb⋅in)
4. Clutch Pedal
5. Return Spring
6. Clevis Pin
7. Shaft
8. Clutch Switch or Stopper Bolt
9. Clutch Pedal and Bracket Assembly
Tighten:
Clutch bracket bolts to 37 N
⋅m (3.8 kg⋅m / 27 lb⋅ft)
• Perform the clutch pedal adjustment after in-
stallation of clutch control.
Clutch Pedal Height and Stroke
1) Loosen the lock nut of the master cylinder push
rod.
2) Adjust the pedal height by turning the push rod.
3) Tighten the lock nut.
Tighten:
Lock nut to 17 N
⋅m (1.7 kg⋅m / 12 lb⋅ft)
4) Install the meter assembly and meter cluster.
Clutch Pedal Free Play
Clutch Switch or Stopper Bolt
After completion of clutch pedal height and slave
cylinder adjustment, adjust the clutch switch or
stopper bolt clearance.
1) Loosen the lock nut of clutch switch or stopper
bolt.
N7A0230E
Clutch Pedal Height and Stroke
mm (in)
Height (A): 160 — 170 (6.3 — 6.7)
Stroke (B): 159 — 169 (6.2 — 6.7)
N7A0009E
CLUTCH 7C-13
2) Adjust the clutch switch or stopper bolt clear-
ance by turning clutch switch or stopper bolt.
3) Tighten the lock nut.
Tighten:
Lock nut to 19 N
⋅m (1.9 kg⋅m / 14 lb⋅ft)
10. Clutch Pipe and Hose
• Perform the clutch hydraulic circuit bleeding af-
ter installation of the clutch control.
Bleeding operation calls for cooperative action
of two men.
1) Check the level of clutch fluid in the reservoir
and replenish if necessary.
2) Remove the rubber cap from the bleeder screw
and wipe clean the bleeder screw.
Connect a vinyl tube to the bleeder screw and
insert the other end of the vinyl tube into trans-
parent container.
3) Pump the clutch pedal repeatedly and hold it
depressed.
4) Loosen the bleeder screw on the clutch slave
cylinder to release clutch to release clutch fluid
with air bubbles into the container and tighten
the bleeder screw immediately.
5) Release the clutch pedal carefully. Repeat the
above operation until air bubbles disappear
from the clutch fluid being pumped out into the
container. During the bleeding operation, keep
the clutch fluid reservoir filled to the specified
level.
Reinstall the rubber cap.
Clutch Switch or Stopper Bolt
Clearance (C)
mm (in)
0.5 — 1.0 (0.02 — 0.04)
Clutch Pedal Free Play
mm (in)
15 — 25 (0.6 — 1.0)
N7A0011E
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