Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 959

7C–6

CLUTCH

Diagnosis

Condition

Possible cause

Correction

Dragging

Fluid leakage.

Repair

Air in hydraulic line.

Bleed

Master cylinder and slave cylinder
seals worn. 

Replace seals.

 Driven plate warped.

Replace driven plate.

Diaphragm spring weakened or tip of
fingers worn. 

Replace pressure plate

Driven plate sticking on splines.

Lubricate with grease or replace.

Clutch spline worn. 

Repair

Release bearing worn or damaged.

Replace release bearing.

Slipping

Driven plate facing worn or oil
soaked.

Replace driven plate and check for
leaks.

Diaphragm spring weakened.

Replace pressure plate.

Pressure plate or flywheel warped.

Correct or replace.

Master cylinder and slave cylinder
seals worn.

Replace seals.

Chattering

Engine mounts loose or damaged.

Tighten or replace.

Driven plate facing warped.

Replace driven plate.

Surface of facing hardened.

Replace driven plate

Driven plate facing oil soaked. 

Replace driven plate and check for
leaks.

Damper springs weakened or
broken. 

Replace.

Pressure plate or flywheel warped.

Correct or replace.

Noisy

Replace bearing binding.

Correct, or replace if damaged, and
lubricate.

Replace bearing worn or damaged. 

Replace release bearing.

Release bearing poorly lubricated. 

Lubricate.

Pilot bearing worn.

Replace pilot bearing.

Damper springs weakened or
broken.

Replace driven plate.

Rivets of driven plate exposed.

Replace driven plate.

Replace driven plate.

Hydraulic line blocked.

Clean out or replace.

Master or slave cylinders binding.

Repair or replace as needed.

CLUTCH

7C–7

Clutch Assembly

Clutch Assembly and Associated Parts

201RW018–1

Legend

(1) Flywheel Assembly and Crankshaft Bearing
(2) Driven Plate Assembly
(3) Pressure Plate Assembly 

(4) Transmission Assembly
(5) Front Cover
(6) Shift Fork
(7) Release Bearing

Removal

1. Remove transmission assembly, refer to ”MANUAL

TRANSMISSION” of Section 7B for ”Removal AND
INSTALLATION” procedure.

2. Remove pressure plate assembly (2).
3. Remove driven plate assembly (1), use the pilot

aligner J-24547 to prevent the driven plate assembly
(1) from falling free.

201RW005

7C–8

CLUTCH

4. Mark the flywheel, clutch cover and pressure plate lug

for alignment when installing. 

5. Remove the release bearing (3) from the

transmission case .

6. Remove the shift fork snap pin.
7. Remove the shift fork pin and shift fork (4) from the

front cover.

8. Remove the front cover bolts.
9. Remove the front cover (5) from the transmission

case. 

220RW088

10. Remove flywheel assembly and crankshaft bearing,

do not remove except for replacement.

11. Use the remover J–5822 and sliding hammer

J–23907 to remove the crankshaft bearing.

015RW050

Inspection and Repair

Make necessary correction or parts replacement if wear,
damage, or any other abnormal condition are found
through inspection.

Pressure Plate Assembly

201RS002

1. Visually check the pressure plate friction surface for

excessive wear and heat cracks.

2. If excessive wear or deep heat cracks are present,

the pressure plate must be replaced.

Pressure Plate Warpage

201RS003

CLUTCH

7C–9

1. Use a straight edge and a feeler gauge to measure

the pressure plate friction surface flatness in four
directions.

2. If any of the measured values exceeds the specified

limit, the pressure plate must be replaced. 

Pressure Plate Warpage 

Limit: 0.3 mm (0.012 in)

Clutch Cover

201RS004

1. Visually check the entire clutch cover for excessive

wear, cracking, and other damage.

2. The clutch cover must be replaced if any of these

conditions are present. 

Clutch Set Force

201RS005

1. Invert the pressure plate assembly.

2. Place a new driven plate over the pressure plate. A

metal sheet with A thickness of 8.3 mm (0.327 in)
may be used in place of the driven plate.

3. Compress the pressure plate assembly until the

distance B becomes 12 mm (0.472  in).

4. Note the pressure gauge reading.
5. If the measured value is less than the specified limit,

the pressure plate assembly must be replaced. 

Clutch Set Force
Standard: 7208 N ( 1621 lb)
Limit: 6468 N (1454 lb)

Diaphragm Spring Finger Height

201RW009

Legend

(1) Release Side

1. Place a new driven plate or a 8.3 mm (0.327 in)

spacer beneath the pressure plate.

2. Fully compress the pressure plate and diaphragm

spring.

3. There are two ways to do this.
4. Use a bench press to press down on the assembly

from the top.

5. Tighten the fixing bolts. 

NOTE: Preload on diaphragm spring finger must be 49 –
98 N (11 – 22 lb) in direction of release, when clutch cover
assembly is bolted to the flywheel. 

6. Measure the spring height from base to spring tip A. If

the measured value exceeds the specified limit, the
pressure plate assembly must be replaced. 

Spring Finger Height

Standard: 49.9 mm – 51.9 mm (1.965 in –
2.043 in)