Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Service manual — part 1041
CLUTCH 7C-23
Release Bearing Replacement
Removal (Except 6VD1)
Use the bearing puller and the adapter to remove the release
bearing.
Bearing Puller : 5-8840-0013-0 (J-22888)
Adapter : 5-8840-0124-0 (J-2241-11)
Release Bearing Installation (Except 6VD1)
1. Set the release bearing to the shift block bearing fitting
surfaces.
The release bearing must be perfectly horizontal.
2. Use a bench press to fit the release bearing to the shift
block.
Install the parts as illustrated after applying wheel bearing
grease or multi-purpose type grease (NLGI No.2 or No.3).
6VD1
Release Bearing (6VD1)
1. Visually check the release bearing for excessive play, noise
and breakage.
If any of these conditions are discovered, the release
bearing must be replaced.
6VD1
NOTE:
When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.
7C-24 CLUTCH
Wedge Collar (6VD1)
1. Visually check the surfaces of the wedge collar making
contact with the release bearing for excessive wear and
damage.
2. Replace any exhibiting excessive wear damage.
Shift Fork (Except 6VD1)
1. Visually inspect the surfaces of the shift fork making contact
with the shift block for excessive wear and damage.
2. Remove any minor stepping or abrasion from the shift block
with an oil stone.
Replace any exhibiting excessive wear or damage.
3. Apply multi-purpose type grease (NLGI No.2 or No.3) to
area.
6VD1
Shift Fork (6VD1)
1. Visually check the surfaces of the shift fork making contact
with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from shift fork with
an oil stone.
Replace any exhibiting excessive wear of damage.
DRIVEN PLATE ASSEMBLY
1. Visually inspect the torsion spring
1
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
2
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.
CLUTCH 7C-25
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 into the driven plate splined
hub.
The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner : 5-8840-2634-0 (HEC Engine Series)
5-8525-3001-0 (J-24547) (Except HEC Engine Series)
2. Set a dial indicator to the driven plate outside
circumference.
3. Slowly turn the driven plate.
Read the dial indicator as you turn the driven plate.
If the measured value exceeds the specified limit, the driven
plate assembly and/or the facing must be replaced.
Driven Plate Warpage
mm(in)
Standard
Limit
0.7 (0.028)
1.0 (0.039)
Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft
spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven
plate.
If the measured value exceeds the specified limit, the driven
plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear
mm(in)
Standard
Limit
0.5 (0.020)
1.0 (0.039)
7C-26 CLUTCH
Rivet Head Depression
Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression
1
from the facing surface
2
.
Be sure to measure the rivet head depression on both sides of
the driven plate.
If the measured value is less than the specified limit, the facing
must be replaced.
Rivet Head Depression
mm(in)
Standard
Fly wheel side
P/Plate side
HEC
1.65
∼
2.25
(0.065-0.089)
4JA1
1.35
∼
1.95
(0.053-0.077)
1.65
∼
2.25
(0.065-0.089)
0.2
(0.008)
4JB1T, 4JG2T
1.3
∼
1.9
(0.051-0.075)
6VD1
1.6 (0.063)
Limit
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