Mitsubishi 380. Manual - part 984

CLUTCH

CLUTCH OVERHAUL

21B-5

>>D<< CLUTCH DISC/CLUTCH COVER INSTALLATION

AK204214

Flywheel

Clutch disc

Clutch disc

guide

Clutch cover

AB

1. Apply Mitsubishi grease to the clutch disc splines and rub it 

in the splines with a brush.

Specified grease:

Mitsubishi Part No. 0101011 or equivalent

2. Use the clutch disc guide to position the clutch disc on the 

flywheel.

3. Install the clutch cover onto the flywheel.

.

>>E<< VALVE PLATE SPRING/VALVE PLATE 
INSTALLATION

AK201696

AK201696AF

Valve plate spring

Release cylinde

Valve plate

Set the spring’s large diameter side to the valve plate side, and 
install the valve plate spring and valve plate.

INSPECTION

M1212001100315

.

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 

discoloration.

3. Check the rivets of the strap plate for looseness. If loose, 

replace the clutch cover.

.

CLUTCH

CLUTCH OVERHAUL

21B-6

CLUTCH DISC

CAUTION

Don't clean the clutch disc in a cleaning solvent.
1. Check the facing for loose rivets, uneven contact, evidence 

of seizure, or deposited oils and greases. If defective, 
replace the clutch disc.

AK300248

Rivet sink

Torsion spring

AB

2. Measure the rivet sink and replace the clutch disc if it is 

below the limit.

Minimum limit: 0.3 mm

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

replace the clutch disc.

4. Combine the clutch disc with the input shaft and check for 

sliding condition and play in the rotating direction. If poor 
sliding condition is evident, clean, reassemble, and recheck. 
If excessive play is evident, replace the clutch disc and/or 
input shaft.

.

CLUTCH RELEASE BEARING

CAUTION

Release bearing is packed with grease. Do not wash it in a 
cleaning solvent.
1. Check for seizure, damage, noise or improper rotation.

2. Check for wear on the surface which contacts the diaphragm 

spring.

3. Check for wear on the surface which contacts the release 

fork. If abnormally worn, replace.

.

RELEASE FORK
If the surface which contacts the bearing is abnormally worn, 
replace.

.

RELEASE FORK SHAFT 
Check the release fork shaft for bend and wear, and replace if 
necessary.

CLUTCH RELEASE CYLINDER

CLUTCH OVERHAUL

21B-7

CLUTCH RELEASE CYLINDER

DISASSEMBLY AND REASSEMBLY

M1212001500302

AK502008AB

1

2

3

4

5

6

7

8

9

11 ± 1 N·m

Disassembly steps 

1.

Push rod

2.

Boot

<<

A

>>

>>

A

<<

3.

Piston assembly

4.

Piston cup

5.

Piston

6.

Conical spring

7.

Cap

8.

Air bleeder

9.

Release cylinder

DISASSEMBLY SERVICE POINT

.

<<A>> PISTON ASSEMBLY REMOVAL

AK305228AB

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

out.

CAUTION

Apply compressed air slowly to prevent brake fluid from 
splashing.
2. Apply the compressed air into the tube mounting hole to 

remove the piston assembly.

Disassembly steps ( つづき )

CLUTCH RELEASE CYLINDER

CLUTCH OVERHAUL

21B-8

REASSEMBLY SERVICE POINT

.

>>A<< PISTON ASSEMBLY INSTALLATION

AK201613

AK201613AD

Piston

Piston cup

AK201614

1. Apply brake fluid to the piston cup and inner surface of the 

release cylinder.

Specified brake fluid:

Brake fluid DOT3 or DOT4

2. Insert the piston assembly into the release cylinder.

INSPECTION

M1212001600161

.

RELEASE CYLINDER
1. Check the bore of the release cylinder for rust, scratches or 

damage.

2. Using a cylinder gauge, measure the inside diameter of the 

release cylinder at about three positions (the deepest, 
middle and brim positions). If the clearance from the outside 
diameter of the piston exceeds the limit, replace the release 
cylinder as an assembly.

Limit: 0.15 mm