6-I

CLUTCH
CONTENTS
CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH DISC ................................................... CYLINDER AND TUBE ....... 73 9 7 11 Service Specifications Torque Specifications
NCSAA-

MASTER PEDAL

................. . ................. ............................ ._......

2 3 4

................................................ .........................

RELEASE CYLINDER RELEASE FORK

. . . . . . . . . . . . . .. .. .. .. .. . . .. . . .. . . 15 ......... ...... 5 6 5 2 2 3

SERVICE ADJUSTMENT PROCEDURES Bleeding ........................................................ Clutch Pedal Inspection and Adjustment

SPECIFICATIONS ............................................. General Specifications ................................... Lubricants ......................................................

TROUBLESHOOTING ....................................... Clutch Chattering Clutch Dragged (Clutch did not Release) Clutch Noisy Clutch Operation Erratic or Rough Clutch Slipping Difficult Gear Shifting (Gear Noise During Shifting) Hard Pedal Effort

CAUTION When servicing clutch assemblies or components, do NOT create dust by sanding, grinding or by cleaning clutch parts with a dry brush or with compressed air. (A water dampened cloth should be used.) The clutch disc contains Asbestos Fibers which can become airborne if dust is created during service operations. Breathing dust containing Asbestos Fibers may cause serious bodily harm.

6-2 SPECIFICATIONS
GENERAL SPECIFICATIONS

CLUTCH - Specifications

Items Clutch operating method Inside diameter of clutch master cylinder Clutch disc Type Facing Size (outside x inside) Number of torsion springs Clutch cover assembly Type Setting load N (Ibs.) Mounting bolt circle diameter Clutch release bearing Type Free travel mm (in.) Clutch release cylinder Cylinder bore diameter mm (in.) mm (in.

2.6LEngine Hydraulic type 15.87 (6248) Single dry disc type 225 x 150 (8.9 x 5.9) 4 (single type) Diaphragm spring strap drive type 4600(1014) 264(10.4) Self-centering type 0 (0) constant contact type mm (in.) 19.05 (75)

3.OL Engine Hydraulic type 15.87 r.6248) Single dry disc type 240 x 160 (9.4 x 6.3) 4 (Dual type) Diaphram spring strap drive type 5500(1213) 276(10.9) Self-centering type 0 (0) constant contacttype 19.05 (.75)

mm (in.)

SERVICE SPECIFICATIONS
Items Standard values Clutch pedal height mm (in.) Clutch pedal clevis pin play mm (in.) Clutch pedal free play mm (in.) Clearance between clutch pedal and floorboard when pedal is depressed mm (in.) Limit Clutch disc rivet sink mm (in.) 186-l 91 (7.3-7.5) l-3 (.04-.I21 8-16 (.31-.63) 35 (1.38) or more Specifications

0.3(.012)

.-

TSB Revision

CLUTCH TORQUE SPECIFICATIONS

Items Clutch to flywheel Release cylinder to transmission case Fulcrum Clutch pedal to pedal bracket Eye bolt Clutch tube flare nut Clutch master cylinderto firewall Clutch pedal bracket Bleeder plug Reservoir band

- Specifications

6-3
NOSVS
Nm 15-22 31-42 31-42 25-35 20-25 13-17 7-8 18-25 8-13 5-7 ft.lbs. 11-15 22-30 2230 18-25 15-18 lo-12 5-7 13-18 7-8 4-5

LUBRICANTS
Items Clutch fluid <2.6 L Engine> Clutch disc spline Clutch release fork shaft bearing Clutch release bearing inner surface Clutch release cylinder push rod and clutch release fork Release cylinder inner surface C3.0 L Engine> Clutch release bearing Clutch release bearing and rocker arm contact surfaces Release fork and fulcrum head contact surfaces Specified lubricants Brake Fluid SAE J1703 (DOT3) MITSUBISHI Genuine Grease Part No. 0101011 or equivalent MITSUBISHI Genuine Grease Part No. 0101011 or equivalent MITSUBISHI Genuine Grease Part No. 0101011 or equivalent MITSUBISHI Genuine Grease Part No.0101011 orequivalent Brake Fluid SAE J1703 (DOT3) MOLYKOTE BR-2 PLUS MOLYKOTE BR-2 PLUS MOLYKOTE BR-2 PLUS As required As required As required As required As required As required As required As required As required Quantity

NO&CD-

rTSB

Revision

6-4 TROUBLESHOOTING
Symptom Clutch slipping l Vehicle will not respond to engine speed during acceleration. l improper vehicle speed l Lack of power during uphill driving Clutch drags or does lot release Probable cause

CLUTCH -Troubleshooting

Remedy Adjust Replace Replace _ ~~

Improper pedal free play Excessive wear of clutch disc facing Hardened clutch disc facing, or oil on surface Damaged pressure plate or flywheel Weak or broken pressure spring

Replace (Refer to GROUP 9. for flywheel: Replace

Excessive clutch pedal free play Interference between pedal and floor panel

Adjust Correct

Pilot bearing worn or broken Clutch disc warped Pressure plate, disc or throwout damaged bearing

Replace (Refer to GROUP 9.) Replace Replace ~~ Repair or replace

Hydraulic system fluid leakage or air mixed in Xfficult gear shifting gear noise during shifting) Excessive pedal free play Hydraulic system fluid leakage or air mixed in Unusual wear or corrosion of clutch disc spline Excessive vibration (distortion) of clutch disc :lutch noisy When clutch is not used A noise is heard after clutch is disengaged A noise is heard when clutch is disengaged A noise is heard when vehicle is suddenly rolled of with clutch partially engaged Improper play of clutch pedal Excessive wear of clt%h disc facing Unusual wear and/or damage of release bearing =

Repair or Replace Replace Replace Adjust Replace Replace

Improper grease on the sliding surface of bearing sleeve Improperly installed clutch assembly or bearing Damaged pilot bearing

Repair Repair -

Replace (Refer to GROUP 9.)

I 7-c. n-..:-:--

CLUTCH - Troubleshooting
Symptom Clutch chatters Probable cause Facing hardened Facing stained with oil or grease

/ Service

Adjustment
Remedy Replace

Procedures

6-5

Repair or replace Replace

Weak or broken disc damper springs

Improper facing contact or disc runout Pressure plate or flywheel warped

Replace Replace (Refer to GROUP 9. for flywheel)

Repair or replace (Refer to GROUP 9.) Repair Repair Repair Repair (Refer to GROUP 21.)

Loose engine mounting

Hard pedal effort Improper lubrication of clutch pedal shaft Improper lubrication of clutch disc

spline
improper lubrication of clutch release lever shaft Improper lubrication of front bearing retainer Clutch operation

Facing stained with grease or oil Facing worn or rivet loose Torsion spring deteriorated or broken

Repair or replace Replace Replace

Lubricate

erratic or rough

Improper lubricant on clutch pedal pivot

Clutch pedal height

Clutch pedal clevis pin play

SERVICE ADJUSTMENT
1.

PROCEDURES

CLUTCH PEDAL INSPECTION AND ADJUSTME!&

Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis pin play (measured at the face of the pedal pad). Standard Standard
L

value

value (A) : 185-191 (B) : l-3 mm

mm (7.3-7.5 (.O&.lZ in.)

in.)

2.
1dehicles i n&o-cruise I system

without
control

VI ahlicles with autocr ui se control system

If either the clutch pedal height or the clutch pedal clevis pin play are not within the standard value range, adjust as follows: (I) For vehicles without auto-cruise control system, turn the stopper bolt to adjust the clutch pedal height to agree with the standard value and then secure the bolt with the lock nut. For vehicles with auto-cruise control system, disconnect the clutch switch connector and turn the switch for standard clutch pedal height. Then lock with the

lock nut.
t

levision

CLUTCH

- Service Adjustment

Procedures

NOTE When the pedal height is lower than the standard value. loosen the bolt or clutch switch, and then turn the push rod to make the adjustment. After making the adjustment, tighten the bolt or clutch switch to reach the pedal stopper, and then lock with the lock nut. (2) Turn the push rod to adjust the clutch pedal clevis pin play to agree with the standard value and then secure the push rod with the lock nut.
oawa29

Clutch pedal free play

Distance between the clutch pedal and the floorboard when the

Caution When adjusting the clutch pedal clevis pin play, be careful not to push the push rod toward the master cylinder. 3. After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the floorboard when the clutch is disengaged are within the standard value ranges. Standardvalue (C) : 8-16 mm (.31-.63 in.) Standard value (D) : 35 mm (1.38 in.) or more 4. If the clutch pedal free play and the distance between the clutch pedal and the floorboard when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system, or a faulty master cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder or clutch.

BLEEDING

Whenever the clutch tube, the clutch hose, and/or the clutch master cylinder have been removed, or if the clutch pedal is spongy, bleed the system. Specified clutch fluid : Brake Fluid SAE 51703 (DOT3) of the

Caution Use the specified brake fluid. Avoid specified fluid and other fluid.

using a mixture

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CLUTCH - Clutch

Pedal

<2.6L

Engine>

6-7
NWA-0

CLUTCH

PEDAL <2.6L

ENGINE>

REMOVAL AND INSTALLATION

Post-installation
l

Adjustment of Clutch Pedal (Refer to P.&5.)

25-35 Nm

Operation

Removal

steps
1. 2. 3. 4. 5. 6. 7. 8. 9. Return spring Cotter pin Washer Clevis pin Clutch pedal bracket Pedal shaft Clutch pedal Bushing Spacer

++ +*I ++ , ++ ++

NOTE (1) Reverse the removal procedures to reinstall. (21 +a : Refer to * Service Points of Installation. (3) m : Non-reusable parts
08W510

INSPECTION
l l l

NWPCAC
l

Check the pedal shaft bushing for wear. Check the pedal arm for bend or torsion. Check the return spring for deterioration.

SERVICE POINTS OF INSTALLATION

9.

?wPDAR

APPLICATION OF GREASE TO SPACER/8. BUSHING/G. PEDAL SHAFT Apply multipurpose grease to the pedal shaft, spacer and bushings. APPLICATION OF GREASE TO CLEVIS PIN/3. WASHER Apply the multipurpose grease to the clevis pin and
washer.

4.

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6-8

CLUTCH - Clutch Pedal <3.OL Engine>

CLUTCH PEDAL <3,OL ENGINE>

REMOVAL AND INSTALLATION
Post-installation
l

Adjustment of Clutch Pedal (Refer to P.65.)

25-35

Operation

Nm

steps 1. Cotter pin +* 2. Return spring 3. Bracket 4. Cotter pin +a 5. Bushing 6. Stopper bolt 7. Clutch switch 8. Cotter pin +a 9. Washer +* 10. Clevis pin ++ 11. Clutch pedal mounting bolt 12. Clutch pedal I)+ 13. Bushings l a 14. Spacer 15. Pedal pad NOTE (1) Reverse the removal procedures to reinstall. (2) + : Refer to Service Points of Installation. (3) b : Non-reusable parts

Removal

INSPECTION
Refer to P.B-7.

SERVICE POINTS OF INSTALLATION

14. APPLICATION OF GREASE TO SPACER/lB. ING/II. CLUTCH PEDAL MOUNTING BOLT
Apply multipurpose bushings. grease to the pedal shaft,

No6PDPI(I
BUSHspacer and

r h%k!li
5.
1 TSB Revision

IO. APPLICATION
Refer to P. 67.

OF GREASE TO CLEVIS

PIN/g.

WASHER

APPLICATION SPRING

OF GREASE
grease

TO BUSHING/2.
to the return

RETURN
spring and

Apply multipurpose bushing.

CLUTCH - Clutch Master Cylinder and Tube

6-9
?aeMez-

CLUTCH

MASTER

CYLINDER

AND TUBE

REMOVAL AND INSTALLATION

,

Pre-removal Operation 0 Drainina of Clutch Fluid

l

Post-installation Operation SupDlvina Clutch Fluid

Clutch master cylinder removal steps 1. Cotter pin 2. Washer I)* 3. Clevis pin 4. Clutch master cylinder 5. Sealer Clutch line removal steps
l e

20-i5 Nm 15-18 ftlbs. gine>

6. 7. +I) l * 8. 9. I)+ 10.

Eye bolt Gasket Clutch hose Hose clip Clutch tube

c2.6LNOTE

Y -5-2 nl iknin-> .Y.b .d.~..m-

moval procedures to reinstall. (I* : Heter to Service Points of RemovaI. )* : Refer to Service Points of Installation q : Non-reusable parts.

SERVICE POINTS OF REMOVAL

8. REMOVAL OF CLUTCH HOSE
hose side, Holding the nut at the clutch nut of the clutch tube.

NlMBAE
loosen the flare

iNSPECTION
l l
14W593

NOMcylinder or clutch hose for fluid leakage.

Check the master Check the clutch

hose or tube

for cracks

or clogging.

SERVICE POINTS OF INSTALLATION

10. INSTALLATION OF CLUTCH TUBE/8. CLUTCH

NWMOAI
HOSE

(1) Temporarily tighten the clutch tube flare nut by hand, and then tighten it to the specified torque, being

careful

that the clutch

hose does not become

twisted.

Se&e side

TSB Revision

6-10

CLUTCH - Clutch

Master

Cvlinder

and

Tube

(2) Connect the clutch hose to the release cylinder at the stepped portion shown in the illustration. (3) After tightening the clutch tube flare nut and eye bolt, check to be sure there is no leakage of the clutch fluid.

3. APPLICATION OF GREASE TO CLEVIS Refer to P. 6-7.

PIN/2.

WASHER

DISASSEMBLY AND REASSEMBLY I

FmsNA-

Disassembly

steps 1. Piston stop ring ++ 2. Damper and push +I) I)+ 3. Piston assembly
4. Reservoir cap

rod

5. Reservoir I)+ 6. Reservoir band 7. Master cylinder body

NOTE (I) Reverse the disassembly (2) +e : Refer to Service (3) l)a : Refer to Service

procedures to reassemble Points of Disassembly. Points of Reassembly.

SERVICE POINTS OF DISASSEMBLY

1. REMOVAL OF PISTON STOP RING Remove the piston stop ring. 3. REMOVAL OF PISTON ASSEMBLY Pull out the piston assembly. Caution 1. Do not damage the master cylinder body and piston assembly. 2. Do not disassemble piston assembly.

INSPECTION
l l l

NOWCAB

Check Check Check

the inside cylinder body for rust or scars. the piston cup for wear or deformation. the piston for rust or scars.

SERVICE POINTS OF REASSEMBLY

6. INSTALLATION OF RESERVOIR BAND After installing the reservoir, tighten the reservoir the range shown in the-:figure. 7 -

Ncaow38
band in

/ TSBRevision

CLUTCH

Clutch Master

Cylinder

and Tube

I Clutch

~ekase

Cylinder

6-11

3. APPLICATION OF CLUTCH FLUID TO PISTON ASSEMBLY Apply specified clutch fluid to the inner surface of the cylinder and to the entire periphery of the piston assembly. Specified clutch fluid : Brake Fluid SAE J1703 (DOT3)

05Y51

CLUTCH RELEASE CYLINDER

REMOVAL AND INSTALLATION
Pre-removal l Draining
l

Operation of Clutch Fluid

Post-installation Operation Supplying Clutcti Fluid 0 Bleeding (Refer to P.B-6.)

Removal

steps 1. Bleeder screw 2. Eye bolt &KIz 3. Gasket l * 4. Connection of clutch hose l a 5. Clutch release cylinder

Ribs.

7-9

ftlbs.

NOTE (1) Reverse the removal procedures to reinstall. (2) I)* : Refer to Service Points of Installation. (3) q : Non-reusable parts

20-25 14-18

ES.

08W520

INSPECTION
l l

ND6HCPrP

Check the clutch release cylinder for fluid leakage. Check the clutch release cylinder boots for damage.

SERVICE POINTS OF INSTALLATION

NOWOAD

5. APPLICATION OF GREASE TO CLUTCH RELEASE CYLINDER Apply a coating of the specified grease to the contact parts of the release fork and release cylinder push rod. Specified 4. grease : MITSUBISHI Genuine Grease Part No. 0101011 or equivalent

CONNECTION OF CLUTCH HOSE (1) Connect the clutch hose to the release cylinder at the stepped portion shown in the illustration. (2) After tightening the eye bolt, check to be sure there is no leakage of the clutch fluid.

tvision

6-12
GASSEMBLY

CLUTCH - Clutch Release Cviinder AND REASSEMBLY

Disassembly
1. 2. 3. 4.

steps
Valve plate Spring

+I) *q

5. 6. 7. 8. 9.

Push rod Boots Piston and cup Conical spring Cap Bleeder plug Release cylinder

08W523 NOTE (1) Reverse the disassembly procedures to reassemble. (2) a+ : Refer to Service Points of Disassembly. (3) +4 : Refer to Service Points of Reassembly.

SERVICE POINTS OF DISASSEMBLY

5. REMOVAL OF PlSTON AND CUP Remove the piston from the release pressed air. cylinder

WsLaAA
using com-

Caution
1. Cover
Out.

with

rags to prevent air slowly

the piston

from

popping

2. Apply compressed from splashing.

to prevent

brake fluid

INSPECTION
(I) Check the inner surface of the release cylinder for scratches or irregular wear. (2) Replace if the piston cup outer circumference is scratched or shows signs of fatigue, or if there is excessive wear of the lip where indicated in the figure.

SERVICE POINTS OF REASSEMBLY

NOSLOAO

5. APPLICATION OF FLUID TO PISTON AND CUP After applying a coating of the specified brake fluid to the inner surface of the release cylinder body and to the entire circumference of the piston and cup, insert the piston and cup into the release cylinder. Specified clutch fluid : Brake Fluid SAE J1703 (DOT 3)

CLUTCH - Clutch

Disc

6-13

CLUTCH
71

DISC

REMOVAL AND INSTALLATION

Removal steps 41) ++ 1. Transmission and transfer assembly 41) l + 2. Clutch cover assembly H 3. Clutch disc

(1I Reverse the removal procedures to reinstall. (21 l * : Refer to Service Points of Removal. (3) +* : Refer to Service Points of Installation.

NOTE

15-21 Nm I 1-15 klbs.

SERVICE POINTS OF REMOVAL

1. ;EX;L OF TRANSMISSION AND TRANSFER ASRefer to GROUP 21 - Transmission and Transfer Assembly. REMOVAL OF CLUTCH COVER ASSEMBLY (1) insert clutch disc guide, or main drive gear of transmission in center spline to prevent dropping of clutch disc. (2) Diagonally loosen bolts retaining clutch cover to flywheel. Back off bolts, one or two turns at a time, in succession, to avoid bending cover flange. Caution DO NOT clean clutch disc or release bearing with cleaning solvent.

2.

CLEANING AND INSPECTION

l

NWGCAE

l l

Clean clutch dust from clutch housing with vacuum brush or shop towel. Do not use compressed air. Inspect for oil leakage through engine rear main bearing oil seal and transmission front oil seal. If leakage is noted, it should be corrected at this time. Friction face of pressure plate should be have a uniform appearance throughout entire disc contact area. If there is evidence of heavy contact on one portion of wear circle and a very light contact 180 degrees from that portion, pressure plate may be improperly mounted or sprung. Friction face of flywheel should also be free from excessive discoloration, burned areas, small cracks, deep grooves, or ridges. Wipe friction surface of pressure plate with a cleaning solvent. Using a straight edge, check pressure plate for flatness. The pressure plate friction area should be flat within 0.5 mm (.020 in.) and free from discoloration, burned area, cracks, grooves or ridges.

/ TSB Revision

6-14

CLUTCH - Clutch
l

Disc

* e

Visually inspect the cover outef mounting flange for flatness. It should be free-of nicks, burrs, dents or other damage. The three dowels on the. flywheel should be tight and undamaged. The cover stamping should be a snug fit on the dowels. if the clutch assembly does not meet these requirements, it should be replaced.

CLUTCH DISC
(1) The disc assembly should be handled without touching facings. Replace disc if facings show evidence of grease or oil soakatie. (2) Use the caliper gauge to measure the dimension from the facing surface to the rivet head. Limit (3) ii;: : 0.3 mm measured (.012 in.) value is below the limit, replace the clutch

(4) Thehub splines and splines on transmission input shaft should be a snug fit without signs of excessive wear: (5) Metallic portions of disc assembly should be dry and clean and show no evidence of having been hot. Each of the arched springs between facings should be unbroken and all rivets should be tight.

SERWCE POINTS OF INSTALLATION

3.
Clutch disc This surface has

NOGGDAJ

INSTALLATION OF CLUTCH DISC/2. CLUTCH COVER ASSEMBLY (I) If there are oils or greases on clutch facing and pressure plate, throughly wipe away with a dry cloth. (2) Lightly specified grease clutch disc spline. Specified grease : MITSUBISHI Gemtine Grease Part No. 0101011 or equivalent

(3) Using clutch disc guide, or main drive gear of transmission, install clutch disc and clutch cover assembly on flywheel. (4) When installing clutch disc, be sure that surface having manufacturers stamped mark is on pressure plate side.

(5) When installing the clutch cover assembly, align the clutch cover assemblys dowel pin hole and the flywheels dowel pin, and then gradually tighten the bolts alternately. 1. INSTALLATION ASSEMBLY OF TRANSMISSION AND TRANSFER Assembly.

Refer to GROUP 21-Transmission 1 1

and Transfer

1 TSB Revision

P ---

CLUTCH - Clutch

Release

Fork

<2.6LEngine>

6-15 NnsR4--I
1

CLUTCH RELEASE FORK <2.6L

REMOVAL AND INSTALLATION

ENGINE>

Removal ++ WI

steps 1. Transmission 2. Return clip

and transfer

assembly

++
++ I)*

3. Clutch release bearing

4. Clutch release fork

5. Clutch release fork boot 6. Fulcrum (2) ** (3) l *

NOTE (1) Reverse the removal procedures to reinstall.

: Refer to Service Points of Removal.. : Refer to Service Points of Installation.

SERVICE POINTS OF REMOVAL

NOSRBAA

1. REMOVAL OF TRANSMISSION AND TRANSFER ASSEMBLY Refer to GROUP 21 - Transmission and Transfer Assembly. 4. REMOVAL OF CLUTCH RELEASE Slide release fork in direction of fulcrum from clip. Caution Attempting to remove release fork direction will result in damage to FORK arrow

to disengage

DCLOOZ

Clutch release bearing

I-

by sliding clip.

it in other

SERVlCE POINTS OF INSTALLATION

NcmDAA

4. APPLICATION OF GREASE TO RELEASE FORK Pack the release fork fulcrum hole with specified grease. Specified grease : MITSUBISHI Genuine Part No. 0101011 OF GREASE TO Grease RELEASE

3. APPLICATION BEARING Pack specified I.D. Specified

CLUTCH

grease in groove

on clutch

release bearing

grease

: MITSUBISHI Genuine Grease Part No. 0101011 or equivalent

fork

1. INSTALLATiON OF TRANSMISSION AND TRANSFER ASSEMBLY Refer to GROUP 21-Transmission and Transfer Assembly.

6-16

CLUTCH - Clutch

Release

Fork

<3.OLEngine>

CLUTCH RELEASE FORK <3.OL ENGINE>

REMOVAL AND INSTALLATION

2
Removal steps +e l + 1. Transmission

+* +*

2. 3. 4. 5. 6.

and transfer assembl Return spring Clutch release bearing Clutch release fork Clutch release fork boot Fulcrum
to reinstall. of Removal. of Installation.

(1) Reverse the removal procedures (2) *I) : Refer to Service Points (3) l + : Refer to Service points

NOTE

Clutch

release

bearing

SERVICE POINTS OF REMOVAL

1.

No6aaAe

REMOVAL OF TRANSMISSION AND TRANSFER ASSEMBLY Refer to GROUP 21 - Transmission and Transfer Assembly.

SERWCE POINTS OF INSTALLATION

Fulcrum

NM)mAa

4. APPLICATION OF GREASE TO RELEASE FORK Pack the release fork fulcrum hole with specified grease. Specified grease : MOLYKOTE OF GREASE BR-2 PLUS TO CLUTCH RELEASE bearing

3. APPLICATION BEARING Pack specified I.D.

Release fork Y

grease in groove : MOLYKOTE

on clutch release BR-2 PLUS

Specified

grease

1. INSTALLATION OF TRANSMISSION AND TRANSFER ASSEMBLY Refer to GROUP 21-Transmission and Transfer Assembly.

( TSB Revision