Mitsubishi L200. Manual — part 240

CLUTCH

CLUTCH OVERHAUL

21B-5

INSPECTION

M1212001100252

CLUTCH COVER

AK403603AB

Diaphragm spring

1. Check the diaphragm spring end for wear and

uneven height. Replace if wear is evident or
height difference exceeds the limit.

Limit: 0.5 mm

2. Check the pressure plate surface for wear, cracks

and seizure.

3. Check the strap plate rivets for looseness and

replace the clutch cover assembly if loose.

CLUTCH DISC

CAUTION

Don't clean the clutch disc in a cleaning solvent.

AK400613

Rivet sink

AC

1. Check the facing for loose rivets, uneven contact,

deterioration due to seizure, adhesion of oil or
grease. Replace the clutch disc if defective.

2. Measure the rivet sink and replace the clutch disc

if it is out of specification.

Limit: 0.3 mm

3. Check for the torsion spring play and damage. If

defective, replace the clutch disc.

4. Combine the clutch disc with the input shaft and

check sliding condition and play in the rotating
direction. If it does not slide smoothly or the play
is excessive, check after cleaning and
reassembling. If the play is excessive, replace the
clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING

CAUTION

The clutch release bearing is packed with grease.
Do not wash it in cleaning solvent.
1. Check the bearing for seizure, damage, noise, or

improper rotation. If defective, replace the
bearing.

2. Check for wear on the surface which contacts with

the diaphragm spring. If abnormally worn, replace
the bearing.

3. Check for wear on the surface which contacts with

the release fork. If abnormally worn, replace the
bearing.

RELEASE FORK
Check for wear on the surface which contacts with
the bearing. If abnormally worn, replace the release
fork.

CLUTCH RELEASE CYLINDER

CLUTCH OVERHAUL

21B-6

CLUTCH RELEASE CYLINDER

DISASSEMBLY AND REASSEMBLY

M1212001500573

AK503444

8.0 ± 1.0 N·m

1

2

3

4

5

6

7

8

9

AE

Disassembly steps

1.

Push rod

2

Boot

<<

A

>>

>>

A

<<

3.

Piston cup B

<<

A

>>

>>

A

<<

4.

Piston

<<

A

>>

>>

A

<<

5.

Piston cup A

6.

Conical spring

7.

Cap

8

Bleeder plug

>>

A

<<

9.

Release cylinder

DISASSEMBLY SERVICE POINT

<<A>> PISTON CUP A / PISTON CUP B / PISTON
REMOVAL

WARNING

•

Cover with a shop towel to prevent the
piston from popping out.

•

AK102083

Apply compressed air slowly to prevent
brake fluid from splashing.

Remove the piston and piston cup from the release
cylinder using compressed air.

CLUTCH RELEASE CYLINDER

CLUTCH OVERHAUL

21B-7

REASSEMBLY SERVICE POINT

>>A<< RELEASE CYLINDER / PISTON CUP A /
PISTON CUP B / PISTON INSTALLATION

AK704100AB

1. Apply brake fluid to the entire inner surface of the

release cylinder.

Specified brake fluid: Brake fluid DOT 3 or
DOT 4

AK203875 AH

Piston

Piston cup

2. Apply grease to the piston and piston cups and

insert the piston assembly into the release
cylinder.

Specified grease: Rubber grease

INSPECTION

M1212001600246

PISTON CUP
Check the lip of piston cup for scratch. If there are
any scratches, check if there are any scores inside
the release cylinder.

RELEASE CYLINDER
1. Check the inner surface of the release cylinder for

rust or scratches.

2. Use a cylinder gauge to measure the inside

diameter of the release cylinder at three different
points (innermost, middle, and outermost points).
Replace the release cylinder assembly if the
clearance between the piston and cylinder
exceeds the limit at any of the measurement
points.

Limit: 0.15 mm

22-1

GROUP 22

MANUAL

TRANSMISSION

(FR)

CONTENTS

MANUAL TRANSMISSION (FR). . . . . . . . . . . . . . . . . . . . . . . . .

22A

MANUAL TRANSMISSION OVERHAUL <R5MB1> . . . . . . . . .

22B

MANUAL TRANSMISSION OVERHAUL <V5MB1> . . . . . . . . .

22C