Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1045

CLUTCH 7C-39

6VD1

Piston and piston cup

Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts shown in the illustration.

Measure the clearance between slave cylinder wall and piston
If the measured value exceeds the specified limit, the slave
cylinder assembly must be replaced.
Slave Cylinder Wall and Piston Clearance

mm(in)

Standard

Limit

0.07 (0.0028)

0.15 (0.0059)

REASSEMBLY

To reassemble, follow the disassembly steps in the reverse
order, noting the following points:

6VD1

1. Piston Assembly

1) Before installing the parts, apply a thin coat of rubber

grease.

2) Install cup in groove in piston with the lip turned to the front

of cylinder. Use care so as not to scratch the cylinder.

7C-40 CLUTCH

HYDRAULEC DAMPER CYLINDER (Except 6VD1 Engine)

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.

Visually check for oil leakage and other damage.
If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.

CLUTCH 7C-41

TROUBLESHOOTING

Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.

(1) checkpoint (2) Trouble Cause (3) Countermeasure

This Section is divided into five sub-sections:

1. Clutch Slippage

2. Clutch Does Not Release Properly

3. Clutch Shudder

4. Clutch Noise

1) Clutch pedal Depressed (Clutch Disengaged)

2) Clutch pedal Not Depressed (Clutch Engaged)

5. Oil Leakage

7C-42 CLUTCH

1. CLUTCH SLIPPAGE

Checkpoint

Trouble Cause

Countermeasure

Adjust the push rod play

No push rod play in the master

cylinder

NG

Clean the related parts and/or
replace the facing

Replace the transmission front
cover oil seal

Clean the related parts and/or

replace the facing

Repair or replace the

transmission front cover

Adjust the push rod play

Defective transmission front

cover oil seal

Continued on the next page

Grease or oil adhering to the

facing

Too much grease

Transmission front cover

unevenly worn

No push rod play in the slave

cylinder

Clean and grease the shift

block

Shift block

Insufficient grease on the front

cover contact surfaces

NG

NG

NG

NG

NG

OK

OK

Clutch pedal free play

OK