Mitsubishi Outlander (2003+). Manual - part 156

CLUTCH

CLUTCH OVERHAUL

21B-5

CLUTCH

DISASSEMBLY AND REASSEMBLY

M1212001000169

 <F5M42>

AK302748

18 ± 3 N·m

35 ± 6 N·m

22 ± 2 N·m

15 ± 1 N·m

18 ± 3 N·m

18 ± 3 N·m

1

7

6

8

11

10

2

3

5

4

9

12

14

13

15

AC

Removal steps

1.

Clutch fluid line bracket

2.

Insulator

3.

Washer

4.

Clutch tube

5.

Union bolt

6.

Union

7.

Gasket

8.

Clutch release cylinder

>>B<<

9.

Clutch cover

>>B<<

10. Clutch disc
11. Return clip
12. Clutch release bearing

<<A>> >>A<<

13. Release fork
14. Release fork boot
15. Fulcrum

Removal steps (Continued)

CLUTCH

CLUTCH OVERHAUL

21B-6

 <W5M42>

AK302278

35 ± 6 N·m

22 ± 2 N·m

15 ± 1 N·m

1

11

10

13

16

12

15

2

3

8

4

14

9

17

18

5

6

7

18 ± 3 N·m

18 ± 3 N·m

18 ± 3 N·m

AC

18 ± 3 N·m

Removal steps

1.

Clutch fluid line bracket

2.

Insulator

3.

Washer

4.

Clutch tube

5.

Clutch tube

6.

Tube clip

7.

Clutch orifice

8.

Union bolt

9.

Union

10. Gasket

11. Clutch release cylinder

>>B<<

12. Clutch cover

>>B<<

13. Clutch disc
14. Return clip
15. Clutch release bearing

<<A>> >>A<<

16. Release fork
17. Release fork boot
18. Fulcrum

Removal steps (Continued)

CLUTCH

CLUTCH OVERHAUL

21B-7

REMOVAL SERVICE POINT

<<A>> RELEASE FORK REMOVAL

Move the release fork in the direction shown to 
remove the clip from the fulcrum.

INSTALLATION SERVICE POINTS

>>A<< RELEASE FORK INSTALLATION

1. Apply Mitsubishi genuine grease part number 

0101011 or equivalent to the illustrated positions 
of the release fork.

2. Install the release fork to the fulcrum.

>>B<< CLUTCH DISC AND CLUTCH COVER 
INSTALLATION

1. Apply Mitsubishi genuine grease part number 

0101011 or equivalent to the clutch disc splines 
and rub it in the splines with a brush.

2. Using the clutch disc guide to position the clutch 

disc on the flywheel.

3. Install the clutch cover onto the flywheel.

INSPECTION

M1212001100100

CLUTCH COVER
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.

AK204409

Fulcrum

Clip

Release fork

AB

AK204410

Apply grease

Apply grease

Apply grease

AB

AK204214

Flywheel

Clutch disc

Clutch disc
guide

Clutch cover

AB

CLUTCH

CLUTCH OVERHAUL

21B-8

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.
NOTE: If contaminated with grease or oil, 
determine the source of the contaminant and 
repair it. 

2. Measure the rivet sink. 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. Place the clutch disc on 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. 
Therefore, do not wash it in a cleaning solvent.
1. Check for seizure, damage, noise or 

binding/rough  rotation.

2. Check for wear on the surface which contacts with 

the diaphragm spring.

3. Check for wear on the surface which contacts with 

the release fork. If abnormally worn, replace.

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

AK300248

Rivet sink

Torsion spring

AB