Mitsubishi L200. Manual — part 239

21B-1

GROUP 21B

CLUTCH

OVERHAUL

CONTENTS

GENERAL SPECIFICATIONS . . . . . .

21B-2

SERVICE SPECIFICATIONS. . . . . . .

21B-2

TORQUE SPECIFICATIONS . . . . . . .

21B-2

LUBRICANTS . . . . . . . . . . . . . . . . . .

21B-2

CLUTCH . . . . . . . . . . . . . . . . . . . . . . .

21B-3

CLUTCH REMOVAL AND INSTALLATION

21B-3

CLUTCH INSPECTION . . . . . . . . . . . . . . . .

21B-5

CLUTCH RELEASE CYLINDER . . . .

21B-6

CLUTCH RELEASE CYLINDER DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

21B-6

CLUTCH RELEASE CYLINDER INSPECTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21B-7

GENERAL SPECIFICATIONS

CLUTCH OVERHAUL

21B-2

GENERAL SPECIFICATIONS

M1212000201356

Item

R5MB1-J-ND1

R5MB1-J-NC,V5MB1

Clutch operating method

Hydraulic type

Clutch disc type

Single dry disc type

Clutch disc size O.D.

× I.D. mm

225

× 150

250

× 160

Clutch cover type

Diaphragm spring type

Clutch cover setting load N

5,394

± 441

5,850

± 470

SERVICE SPECIFICATIONS

M1212000300286

Item

Limit

Diaphragm spring end height difference mm

0.5

Facing rivet sink mm

0.3

Release cylinder I.D. to piston O.D. clearance mm

0.15

TORQUE SPECIFICATIONS

M1212001800347

Item

N

⋅m

Fulcrum

35

± 6

Clutch release cylinder mounting bolt

35

± 6

Clutch cover mounting bolt

19

± 3

Air bleeder

8.0

± 1.0

LUBRICANTS

M1212000400681

Items

Specified lubricants

Quantity

Clutch release bearing to release fork
contact surface

Mitsubishi Part No. 0101011 or equivalent

As required

Fulcrum to release fork contact surface
Clutch release cylinder push rod to release
fork contact surface
Clutch release bearing inside
Clutch disc spline
Clutch release cylinder inner surface

Brake Fluid DOT 3 or DOT 4

Piston and piston cups outer surface

Rubber grease

CLUTCH

CLUTCH OVERHAUL

21B-3

CLUTCH

DISASSEMBLY AND REASSEMBLY

M1212001001065

AK403591

1

2

3

4

5

6

7

3

35 ± 6 N·m

19 ± 3 N·m

35 ± 6 N·m

8

AB

Removal steps

>>

C

<<

1.

Clutch cover

>>

C

<<

2.

Clutch disc

3.

Return clip

>>

B

<<

4.

Clutch release bearing

5.

Clutch release cylinder

6.

Boot

<<

A

>>

>>

A

<<

7.

Release fork

8.

Fulcrum

DISASSEMBLY SERVICE POINT

<<A>> RELEASE FORK REMOVAL

AK403602 AB

Fulcrum

Release fork

Clip

Slide the release fork in direction of the arrow and
disengage the fulcrum from the clip to remove the
release fork. Be careful not to damage the clip by
pushing the release fork in the wrong direction or
removing it with force.

CLUTCH

CLUTCH OVERHAUL

21B-4

REASSEMBLY SERVICE POINTS

>>A<< RELEASE FORK INSTALLATION

AK403592AB

Fulcrum

Release fork

Clutch release cylinder

1. Apply the specified grease to the release fork.

Specified grease: Mitsubishi Part No.
0101011 or equivalent

2. Install the release fork onto the fulcrum.

>>B<< CLUTCH RELEASE BEARING
INSTALLATION

AK503501AB

1. Apply the specified grease to the clutch release

bearing inside, and fill grease in the groove.

Specified grease: Mitsubishi Part No.
0101011 or equivalent

2. Install the clutch release bearing on the bearing

retainer of the transmission.

3. Install the return clip to engage the clutch release

bearing with the fork.

>>C<< CLUTCH DISC / CLUTCH COVER
INSTALLATION

AK403594

Clutch disc

Flywheel

Clutch cover

Clutch disc guide

AB

1. Apply the specified grease to the clutch disc

splines and rub it in splines with a brush.

Specified grease: Mitsubishi Part No.
0101011 or equivalent

2. Using the clutch disc guide to position the clutch

disc on the flywheel.

AK500601

1

5

4

2

3

7

8

6

Dowel pin
position

:

AE

3. Install the clutch cover, aligning its installation

position with the dowel pins, and then tighten the
bolts to the specified torque of 19

± 3 N⋅m in the

order shown in the illustration.