Mitsubishi L200. Manual — part 237

21-1

GROUP 21

CLUTCH

CONTENTS

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

21A

CLUTCH OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21B

21A-1

GROUP 21A

CLUTCH

CONTENTS

GENERAL INFORMATION . . . . . . . .

21A-2

SERVICE SPECIFICATION(S) . . . . .

21A-2

LUBRICANT(S) . . . . . . . . . . . . . . . . .

21A-2

ON-VEHICLE SERVICE. . . . . . . . . . .

21A-2

CLUTCH PEDAL CHECK AND ADJUSTMENT

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

21A-2

CLUTCH BLEEDING . . . . . . . . . . . . . . . . .

21A-3

CLUTCH PEDAL . . . . . . . . . . . . . . . .

21A-4

CLUTCH PEDAL REMOVAL AND INSTALLATION

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

21A-4

INSPECTION . . . . . . . . . . . . . . . . . . . . . . .

21A-5

CLUTCH PEDAL SWITCH OPERATING CHECK

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

21A-5

CLUTCH MASTER CYLINDER . . . . .

21A-5

CLUTCH MASTER CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION . . . . . . . .

21A-5

CLUTCH MASTER CYLINDER ASSEMBLY
DISASSEMBLY AND REASSEMBLY . . . . .

21A-6

CLUTCH MASTER CYLINDER ASSEMBLY
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . .

21A-6

CLUTCH RELEASE CYLINDER . . . .

21A-7

CLUTCH RELEASE CYLINDER ASSEMBLY
REMOVAL AND INSTALLATION . . . . . . . .

21A-7

CLUTCH CONTROL INSPECTION. . . . . . .

21A-7

GENERAL INFORMATION

CLUTCH

21A-2

GENERAL INFORMATION

M1211000100308

The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.

SERVICE SPECIFICATIONS

M1211000300421

Item

Standard value

Clutch pedal height mm

183.5

− 186.5 <LHD>

178.5

− 181.5 <RHD>

Clutch pedal clevis pin play mm

1

− 3

Clutch pedal free play mm

4

− 13

Distance between the clutch pedal and the floorboard when
the clutch is released mm

91 or more <LHD>
86 or more <RHD>

LUBRICANTS

M1211000400257

Item

Specified lubricant

Quantity

Clutch fluid

Brake Fluid DOT 3 or DOT 4

As required

Pushrod assembly

Rubber grease

As required

Release cylinder pushrod

MITSUBISHI genuine grease Part
No.0101011 or equivalent

As required

ON-VEHICLE SERVICE

CLUTCH PEDAL CHECK AND
ADJUSTMENT

M1211000900940

1. Turn back the carpet etc. under the clutch pedal.

AC001133

Clutch pedal height

Clutch pedal clevis pin play

A

B

AD

2. Measure the clutch pedal height. If the height is

outside the standard value, go to step 4.

Standard value (A):

183.5

− 186.5 mm <LHD>

178.5

− 181.5 mm <RHD>

3. Measure the clutch pedal clevis pin play. If the

play is outside the standard value, go to Step 5.

Standard value (B): 1

− 3 mm

4. Remove the clutch switch. (Refer to

P.21A-4

.)

<Vehicles with cruise control>

ON-VEHICLE SERVICE

CLUTCH

21A-3

CAUTION

Do not push in the master cylinder pushrod at
this time, otherwise the clutch will not operate
properly.

AC502646

Setting nut

Clutch pedal

13 ± 2 N·m

AC

Locking nut

Adjusting bolt

Pushrod

5. If the clutch pedal height is not within the standard

value, loosen the setting nut and the locking nut
<Vehicles without cruise control> to adjust the
clutch pedal height to the standard value and
move the pushrod and the adjusting bolt
<Vehicles without cruise control>.

6. Install the clutch switch. (Refer to

P.21A-4

.)

<Vehicles with cruise control>

7. If the clutch pedal clevis pin play is not within the

standard value, loosen the setting nut and move
the pushrod to adjust.

AC001135AB

D

Distance between the clutch pedal
and the floorboard when the clutch
is disengaged

C

Clutch pedal free play

8. After the adjustments, confirm that the clutch

pedal free play (measured at the face of the pedal
pad) and the distance between the clutch pedal
(the face of the pedal pad) and the floorboard
when the clutch is disengaged are within the
standard value ranges.

Standard value (C): 4

− 13 mm

Standard value (D):

91 mm or more <LHD>
86 mm or more <RHD>

9. If the measured free play and distance do not

agree with the standard value ranges, it is
probably the result of either air in the hydraulic
system or a faulty master cylinder or clutch. Bleed
the air, or disassemble and inspect the master
cylinder or clutch.

10.Reinstall the carpet, etc.

CLUTCH BLEEDING

M1211001400733

CAUTION

Use the specified brake fluid. Do not mix brake
fluids.

Specified fluid: Brake fluid DOT 3 or DOT 4

AC609129

Clutch damper
assembly

AC

Clutch release
cylinder assembly

1. Connect a hose with a bottle to the bleeder screw.
2. Open the bleed nipple.
3. Depress the clutch pedal slowly. Open the bleeder

screw to let air and brake fluid out. Close the
bleeder screw. Release the clutch pedal. Repeat
until only brake fluid and no air comes out.

4. After air bleeding, tighten the bleeder screw to the

specified torque.

Tightening torque: 8.9

± 0.9 N⋅m

5. Check that the brake fluid reservoir level stays

between "MAX" and "MIN" marks throughout the
clutch bleeding process.