Mitsubishi Outlander (2003+). Manual - part 155

21B-1

GROUP 21B

CLUTCH 

OVERHAUL

CONTENTS

HOW TO USE THIS MANUAL. . . . . .

21B-2

GENERAL SPECIFICATIONS . . . . . .

21B-4

SERVICE SPECIFICATIONS. . . . . . .

21B-4

TORQUE SPECIFICATIONS . . . . . . .

21B-4

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

21B-4

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

21B-5

DISASSEMBLY AND REASSEMBLY . . . . . 

21B-5

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

21B-7

CLUTCH RELEASE CYLINDER  . . . .

21B-9

DISASSEMBLY AND REASSEMBLY . . . . . 

21B-9

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

21B-10

HOW TO USE THIS MANUAL

CLUTCH OVERHAUL

21B-2

HOW TO USE THIS MANUAL

M1212002400074

This manual describes service procedures performed after removal of the transmission from the vehicle. 
For removal of the transmission from the vehicle, installation of the transmission in the vehicle, and on-vehicle inspection 
and service of the transmission, please use the separate Workshop Manuals prepared for the vehicle.

(1) A component part drawing is shown at the beginning of each section to enable the technician to ascertain the installed conditi-
     on of the component parts.
(2) Service steps are indicated by means of numbers in the component part drawing. Non-reusable parts are indicated as such, 
     and tightening torques are shown.
    ·Removal steps:
     The numbers of the part names match the numbers in the component part drawing and indicate the removal sequence.
    ·Installation steps:
     Installation steps are omitted wherever installation can be achieved simply by performing the removal steps in reverse.
    ·Disassembly steps:
     The numbers of the part names match the numbers in the component part drawing and indicate the disassembly sequence.
    ·Reassembly steps:
     Reassembly steps are omitted wherever reassembly can be achieved simply by performing the disassembly steps in reverse.

HOW TO USE THIS MANUAL

How to Read Explanations

Scope of Service Explanations

Service steps

Classification of Service Points

Key service points, service standards, and instructions 
for using special tools are collated as service points and 
explained in detail.

<<A>>: Outward-pointing brackets denote removal service points 
             or disassembly service points.
>>A<<: Inward-pointing brackets denote installation service points 
             or reassembly service points.

Every location where a lubricant or sealant must be ap-
plied or added is indicated using a relevant symbol in the 
component part drawing and/or on the page after the 
component part drawing.

Lubricant and Sealant Symbols

. . . . . . . . . . Grease

. . . . . . . . . . Sealant or form-in-place gasket (FIPG)

. . . . . . . . . . Brake fluid

. . . . . . . . . . Gear oil

If an inspection reveals a defect or fault, effect a repair and, if necessary, replace relevant parts.

Inspection

AK300001

HOW TO USE THIS MANUAL

CLUTCH OVERHAUL

21B-3

  

 Disassembly steps

                            1. Spring washer
                            2. Stopper bracket
<<A>>   >>E<<   3. Lock pin
                            4. Interlock plate
                            5. Control finger

  

 Disassembly steps

              >>D<<   6. Spring pin 
                            7. Stopper body
                            8. Spring
                            9. Control shaft

DISASSEMBLY SERVICE POINTS

<<A>> LOCK PIN REMOVAL
Drive out the lock pin from the direction shown.

OVERHAUL CONTROL HOUSING

   22-43

CONTROL HOUSING

DISASSEMBLY AND REASSEMBLY

Section title

Page number

The alphabetical character in this category of 
heading matches that of the relevant removal 
steps, installation steps, disassembly steps, 
or installation steps.

Tightening torque

Denotes non-reusable part.

Procedures and cautions for removal, instal-
lation, disassembly, and reassembly are ex-
plained under this category of heading.

AK302746

AK302747

11

7

8

1

6

5

4

2

3

13

14

12

10

9

22.3 ± 0.3 N·m

AB

AK204273

Lock pin

Control 
finger

AB

GENERAL SPECIFICATIONS

CLUTCH OVERHAUL

21B-4

GENERAL SPECIFICATIONS

M1212000200182

SERVICE SPECIFICATIONS

M1212000300156

TORQUE SPECIFICATIONS

M1212001800154

LUBRICANTS

M1212000400120

Item

Specification

Combined engine

4G63-D4-MPI

4G69-S4-MIVEC

Clutch operating method

Hydraulic type

Clutch disc type

Single dry disc type

Clutch disc size OD 

×

 ID mm

230 

×

 155

Clutch cover type

Diaphragm spring type

Clutch cover setting load N

4,320

5,200

Item

Limit

Diaphragm spring end height difference

0.5 mm

Clutch disc facing rivet sink

Minimum 0.3 mm

Release cylinder I.D. to piston O.D.

0.15 mm

Part

N

⋅

m

Clutch fluid line bracket bolt

18 

±

 3

Clutch tube flare nut

15 

±

 1

Clutch orifice mounting bolt <W5M42>

18 

±

 3

Union bolt

22 

±

 2

Clutch release cylinder mounting bolt

18 

±

 3

Clutch cover mounting bolt

18 

±

 3

Fulcrum

35 

±

 6

Air bleeder

17 

±

 1

Item

Specified lubricant

Release fork and release bearing contact surface

MITSUBISHI genuine grease Part 
Number 0101011 or equivalent

Release fork and fulcrum contact surface
Release fork and release cylinder pushrod contact surface
Clutch disc splines
Piston and piston cup

Brake fluid DOT3 or DOT4

Release cylinder inner surface