Mitsubishi L200. Manual - part 238

CLUTCH PEDAL

CLUTCH

21A-4

CLUTCH PEDAL

REMOVAL AND INSTALLATION

M1211001601008

Pre-removal Operation
• Lower Panel Assembly Removal (Refer to GROUP 52A − 

Instrument Panel Assembly ).

• Drivers side under cover <Except vehicles Single cab> 

Removal (Refer to GROUP 52A 

− Instrument Panel 

Assembly ).

• ETACS-ECU Removal. <LHD>

Post-installation Operation
• ETACS-ECU Installation. <LHD>
• Drivers side under cover <Except vehicles Single cab> 

Installation (Refer to GROUP 52A 

− Instrument Panel 

Assembly ).

• Lower Panel Assembly Installation (Refer to GROUP 52A 

− Instrument Panel Assembly ).

• Clutch Pedal Adjustment (Refer to 

P.21A-2

).

AC900934

7

1

2

3

13 ± 2 N·m

AB

12 ± 2 N·m

9

6

8

12 ± 2 N·m

10

7

13 ± 2 N·m

13 ± 2 N·m

4

5

<Vehicles with
  cruise control>

<Vehicles without
  cruise control>

N

Removal steps 

1.

Snap pin

2.

Clevis pin

3.

Clutch pedal assembly

4.

Adjusting bolt <Vehicles without 
cruise control>

>>

A

<<

5.

Clutch switch <Vehicles with cruise 
control>

6.

Return spring

7.

Bushing

8.

Stopper

9.

Pedal stopper

10. Pedal pad

INSTALLATION SERVICE POINT

>>A<< CLUTCH SWITCH <VEHICLES WITH 
CRUISE CONTROL> INSTALLATION

AC309757

AC

Clutch pedal

Clutch switch

0.5 – 1.0 mm

Install the clutch switch at the specified dimension 
when the clutch pedal is released.

CLUTCH MASTER CYLINDER

CLUTCH

21A-5

INSPECTION

CLUTCH SWITCH CONTINUITY CHECK

M1211001000263

CAUTION

Do not apply grease or lubricant to the switch 
and the switch installation section to avoid mal-
function of the switch. In addition, do not use 
gloves which have grease on them.

AC807040

Open circuit

Continuity

4.0 ± 1.0 mm

AB

Plunger

Clutch switch

1. Check for continuity between the terminals of the 

switch.

Tester 
connection

Plunger 
condition

Specified 
condition

1-2

Released

Continuity (less 
than 2 

Ω)

Pushed

Open circuit

2. If the continuity is incorrect, replace the clutch 

switch.

CLUTCH MASTER CYLINDER

REMOVAL AND INSTALLATION

M1211050100068

Pre-removal Operation
Clutch Fluid Draining

Post-installation Operation
• Clutch Fluid Supplying

• Clutch Bleeding (Refer to 

P.21A-3

).

• Clutch Pedal Adjustment (Refer to 

P.21A-2

).

AC809413

1

2

3

4

13 ± 2 N·m

AD

15 ± 2 N·m (Except High rider 4WD)
18 ± 2 N·m (High rider 4WD)

Clutch master cylinder removal 
steps 

•

Lower panel assembly (Refer to 
GROUP 52A 

− Instrument Panel 

Assembly ).

1.

Snap pin

2.

Clevis pin

3.

Clutch master cylinder assembly

4.

Sealer

Clutch master cylinder removal 
steps (Continued)

CLUTCH MASTER CYLINDER

CLUTCH

21A-6

DISASSEMBLY AND REASSEMBLY

M1211002100542

CAUTION

Do not disassemble the piston assembly.

AC712190

13 ± 2 N·m

N

1

2

3

4

6

7

5

N

Piston repair kit

Clutch fluid:
Brake fluid DOT3 or DOT4

Grease: Rubber grease

AB

8

1

2

3

3

3

Disassembly steps 

1.

Piston stopper ring

>>

A

<<

2.

Pushrod assembly

3.

Piston assembly

4.

Reservoir cap

5.

Spring pin

6.

Reservoir tank

7.

Seal

8.

Master cylinder body

REASSEMBLY SERVICE POINT

AC800214AB

120.4    122.4 mm

>>A<< PUSHROD ASSEMBLY INSTALLATION
Set the length of the pushrod assembly to the dimen-
sion shown to make the adjustment of the clutch 
pedal easier.

INSPECTION

M1211002200196

• Check inside the cylinder body for rust and scars.

• Check the piston for rust and scars.

• Check the pipe connection for clogging.

CLUTCH RELEASE CYLINDER

CLUTCH

21A-7

CLUTCH RELEASE CYLINDER

REMOVAL AND INSTALLATION

M1211005500129

Pre-removal Operation
Clutch Fluid Draining

Post-installation Operation
• Clutch Fluid Supplying

• Clutch Bleeding (Refer to 

P.21A-3

).

• Clutch Pedal Adjustment (Refer to 

P.21A-2

).

AC903922

15 ± 2 N·m

5

3

30 ± 3 N·m

2

11 ± 2 N·m

6

7

8

N

1

N

4

23 ± 2 N·m

35 ± 6 N·m

23 ± 2 N·m

48 ± 6 N·m

15 ± 2 N·m

 <Except High rider, 4WD)>

9 10

Release fork

Release cylinder
pushrod

Specified grease:
MITSUBISHI genuine grease
PART No. 0101011 or equivalent

3

4

23 ± 2 N·m

1

2

3

N

N

5

7

8

23 ± 2 N·m

35 ± 6 N·m

15 ± 2 N·m

30 ± 3 N·m

11 ± 2 N·m

48 ± 6 N·m

6

18 ± 2 N·m

 <High rider, 4WD>

9

10

AB

Clutch release cylinder assembly 
and clutch damper assembly 
removal steps 

•

Side rubber cover rear (front 
wheelhouse left side).

1.

Eye bolt 

2.

Gasket

3.

Clutch release cylinder assembly

4.

Clutch pipe

5.

Eye bolt

6.

Gasket

7.

Clutch hose

8.

Clutch damper assembly

9.

Clutch damper bracket

10. Clutch damper

INSPECTION

M1211002000200

• Check the clutch fluid line for fluid leakage.

• Check the clutch hose and pipe for cracks or 

clogging.

Clutch release cylinder assembly 
and clutch damper assembly 
removal steps (Continued)