GROUP 21 CLUTCH

SPECIFICATIONS ............................................................................. 21-2

STRUCTURE AND OPERATION

1. Clutch Control ............................................................................ 21-3
2. Clutch Master Cylinder ............................................................... 21-4
3. Clutch Proper and Clutch Direct Power Cylinder ........................ 21-5

TROUBLESHOOTING ...................................................................... 21-7

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Replacement of Brake Fluid (Clutch System) ............................... 21-8
2. Air Bleeding of Brake Fluid (Clutch System) .............................. 21-10
3. Inspection of Clutch Disc Wear Limit ........................................ 21-12

CLUTCH PEDAL ............................................................................. 21-14

CLUTCH MASTER CYLINDER ...................................................... 21-17

CLUTCH PROPER .......................................................................... 21-18

CLUTCH CONTROL ......................................................................... 21-22

21-1
SPECIFICATIONS
Item Specifications
Clutch model C3W28 C5W33
Drive type Strap drive
Clutch disc type Dry, single plate type
Pressure plate type Diaphragm spring type
Control system Fluid pressure type
Clutch master cylinder manufacturer NISSIN KOGYO
Clutch direct power cylinder manufacturer NISSIN KOGYO

21-2
STRUCTURE AND OPERATION 21
1. Clutch Control

• Fluid pressure is used to control the clutch operation.

• When the clutch pedal is pressed, the boosted force is then applied to the clutch master cylinder. This pressurizes
the brake fluid inside the clutch master cylinder, pushing the clutch direct power cylinder and disengaging the
clutch.

21-3
STRUCTURE AND OPERATION
2. Clutch Master Cylinder

2.1 When clutch pedal is pressed

• The piston is pushed to the right by the
push rod, pressurizing the brake fluid
in the cylinder.
• This brake fluid pressure is transmit-
ted to the clutch direct power cylinder.

2.2 When clutch pedal is released

• The piston is pushed back to the left
by the combined force of oil pressure
from the clutch direct power cylinder
and the return spring.
• This opens up the port that has been
blocked by the pressure cup, connect-
ing the cylinder to the brake fluid tank.
This allows the oil pressure to com-
pletely drain to the tank.

21-4
 21
3. Clutch Proper and Clutch Direct Power Cylinder

• Clutch engagement and disengagement are controlled by the brake fluid pressure from the clutch master cylinder
acting on the piston of the clutch direct power cylinder, and are achieved by the operation of the piston and the re-
lease bearing.

21-5
STRUCTURE AND OPERATION
3.1 When clutch pedal is released
• There is no brake fluid pressure acting
on the clutch direct power cylinder.
The piston and release bearing remain
in their home positions.
• The force of the diaphragm spring acts
on the pressure plate, which in turn
keeps the clutch disc pressed against
the flywheel.
• Pressed against the flywheel, the
clutch disc rotates together with the
flywheel and transmits the engine
power to the transmission drive pinion.

3.2 When clutch pedal is pressed

• Brake fluid pressure from the clutch
master cylinder moves the piston in
the clutch direct power cylinder.
• As it moves, the piston pushes the re-
lease bearing, which in turn pushes
the diaphragm spring.
• The diaphragm spring pivots around
the pivot ring. This movement, via the
strap plate, causes the pressure plate
to retract from the flywheel. As a re-
sult, the clutch disc separates from the
flywheel, cutting off the transmission of
engine power to the transmission.

21-6
TROUBLESHOOTING 21
Symptoms

Clutch makes noise on disengagement

Clutch pedal requires too much effort

Clutch makes noise on engagement
Clutch does not engage smoothly
Clutch disengaged but drags

Judder when vehicle starting

Reference Gr

Clutch slips
Possible causes
Diaphragm spring heights uneven O O O O
Diaphragm spring fatigued O O
Clutch cover Pressure plate warped or faulty O O O O
Loose rivets O O O
Strap plate bent O O O O
Disc deformed O O O
Disc rivets loose O O
Disc torsion spring fatigued or damaged O
Spline worn O O O
Clutch disc
Spline rusted O O O
Facing worn O
Facing surface hardened O O O
Facing oily or greasy O O
Pedal free play insufficient O O
Pedal free play excessive O O
Clutch pedal
Pedal stroke insufficient O
Pedal sliding part faulty O O O
Piston and pressure cup sliding movement
O O O O
faulty
Clutch master cylinder
Spring fatigued O
Brake fluid passage port clogged O O O O
Piston and piston cup sliding movement
O O O O
faulty
Clutch direct power cylin-
der Brake fluid passage port clogged O O O O
Release bearing faulty O O O
Transmission drive pinion spline worn O O Gr22
Engine idling speed too low O O Gr13A
Engine mounting fatigued O
Flywheel warped, deformed or worn forming steps O O O O Gr11
Flywheel pilot bearing faulty O
Air mixed in clutch hydraulic system O
Clutch hydraulic system leaking O

21-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Replacement of Brake Fluid (Clutch System)
• Clutch fluid (brake fluid) is shared by the clutch and brake systems, and is divided in the brake fluid tank into the
two systems. This section describes the replacement of the clutch fluid (brake fluid) for the clutch system. In order
to completely replace the clutch fluid (brake fluid), the brake fluid in the brake system should also be replaced.
(See Gr35.)

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Bleeder screw 6.9 to 8.8 {0.7 to 0.9} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Brake fluid (SAE J1703 or FMVSS
– Brake fluid tank As required
No. 116 DOT3)

CAUTION
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork.
• If brake fluid is spilled onto the paintwork, immediately wipe it off.
• Be sure to use new brake fluid (SAE J1703 or FMVSS No. 116 DOT3). Do not mix it with brake fluid of dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter the original properties of FUSO brake fluid, causing the boiling point to drop as well as the clutch
rubber parts to swell. Faulty operation of the clutch will result.
• Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty
clutch operation.
• Use a mug exclusively kept for the specified brake fluid. This ensures that no brake fluid of different prop-
erties or mineral oil enter into the system.

1.1 Work before replacement

• Install one end of a vinyl pipe onto the bleeder screw. Place the
loose end into a container.

21-8
 21
1.2 Replacement of brake fluid
• Replace the brake fluid in the following sequence.
CAUTION
• Replacement of old brake fluid with new brake fluid in the
clutch fluid line can be recognized by a change in color of
the brake fluid being discharged through the vinyl pipe.

Loosen the bleeder screw.

Press and release the clutch pedal repetitively until

brake fluid is no longer discharged.

Fill brake fluid up to the “MAX” level on the brake fluid

tank.

Tighten the bleeder screw.

Cycle the clutch pedal several times, then press and

hold the pedal.

Loosen the bleeder screw to discharge the brake fluid.

Air in brake fluid No air in brake fluid

Tighten the bleeder screw.

Release the clutch pedal and wait for at least

one second.

Add brake fluid up to the “MAX” level on the

tank.

Tighten the bleeder screw to the specified torque.

Release the clutch pedal.

Add brake fluid up to the “MAX” level on the tank.

Finish

21-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
2. Air Bleeding of Brake Fluid (Clutch System)
• Clutch fluid (brake fluid) is shared by the clutch and brake systems, and is divided in the brake fluid tank into the
two systems. This section describes the air bleeding procedures for the clutch system. For air bleeding proce-
dures for the brake system (See Gr35.)

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Bleeder screw 6.9 to 8.8 {0.7 to 0.9} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Brake fluid (SAE J1703 or FMVSS
– Brake fluid tank As required
No. 116 DOT3)

CAUTION
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork.
• If brake fluid is spilled onto the paintwork, immediately wipe it off.
• Be sure to use new brake fluid (SAE J1703 or FMVSS No. 116 DOT3). Do not mix it with brake fluid of dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter the original properties of FUSO brake fluid, causing the boiling point to drop as well as the clutch
rubber parts to swell. Faulty operation of the clutch will result.
• Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty
clutch operation.
• Use a mug exclusively kept for the specified brake fluid. This ensures that no brake fluid of different prop-
erties or mineral oil enter into the system.

2.1 Work before air bleeding

• Install one end of a vinyl pipe onto the bleeder screw. Place the
loose end into a container.

21-10
 21
2.2 Air bleeding of brake fluid
• Bleed the air in the following sequence.

Fill brake fluid up to the “MAX” level on the brake fluid

tank.

Cycle the clutch pedal several times, then press and

hold the pedal.

Loosen the bleeder screw to discharge the brake fluid.

Air in brake fluid No air in brake fluid

Tighten the bleeder

screw.

Release the clutch

pedal and wait for at
least one second.

Tighten the bleeder screw to the specified torque.

Release the clutch pedal.

Add brake fluid up to the “MAX” level on the tank.

Finish

21-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
3. Inspection of Clutch Disc Wear Limit
• Remove grommet from the clutch housing, and check to see if
the rod of clutch direct power cylinder has reached the flange of
the release bearing.
• If the rod has reached the flange, replace the clutch disc.

21-12
 21
M E M O

21-13
CLUTCH PEDAL

Removal sequence
1 Clevis pin 8 Cylinder bracket
2 Clutch master cylinder (See later section.) 9 Booster bracket
3 Clevis pin 10 Clutch switch
4 Spring holder 11 Pedal pad
5 Return spring 12 Clutch pedal
6 Plate
7 Spring assist rod

Installation sequence
Follow the removal sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
Clearance between push rod and piston of clutch mas-
2 0.2 to 1.2 – Adjust
ter cylinder
205 N
5 Return spring load (installed length: 35.6) 225 N {23.1 kgf} Replace
{20.8 kgf}
10, 12 Clearance between clutch switch and clutch pedal 0.1 to 1.5 – Adjust
12 Clutch pedal free play 0.2 to 4.0 – Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (booster bracket mounting)
Nut (clutch pedal mounting) 9 to 14 {0.9 to 1.4} –
Nut (clutch master cylinder)
Nut (push rod of master cylinder mounting) 15 to 20 {1.5 to 2.0} –

21-14
 21
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Sliding surface of spring holder
Sliding surface of return spring
Sliding surface of plate Chassis grease
As required
[NLGI No. 1 (Li soap)]
Inside surface of bushing in clutch pedal through which
clevis pin for connecting clutch master cylinder to spring
assist rod is inserted.

Removal procedure
Removal: Spring assist rod
• Loosen the lock nut to release the load on the return spring.
Then, remove the clevis pin and remove the spring assist rod.

Work after installation

Adjustment: Return spring
• Tighten the lock nut such that the return spring is set to the illus-
trated length.

Adjustment: Clutch pedal

• Adjust the push rod of the clutch master cylinder such that the
distance between the center of the clutch pedal pad and the cen-
ter of the clutch master cylinder is set to the value indicated in
the drawing.

21-15
CLUTCH PEDAL
Inspection: Clutch pedal free play
• After installing the clutch master cylinder, check the clutch pedal
free play as follows.
• Using a finger, press the clutch pedal pad in the center until re-
sistance is felt. Measure the distance that the pedal has trav-
eled.
NOTE
• Do not press the clutch pedal pad until a second resistance
is felt (which is the point at which the clutch master cylin-
der’s push rod contacts the piston).

• If the measured distance does not conform to the standard val-

ue, replace the clutch pedal.

Adjustment: Clearance between push rod and piston of

clutch master cylinder
• Adjust the clearance between the clutch master cylinder’s push
rod and piston by using the clutch pedal as follows.
• Using a finger, press the clutch pedal in the center.
• Set the pedal travel, from the point at which the first resistance is
felt to the point at which the second resistance is felt, to the illus-
trated value. (This distance corresponds to the clearance be-
tween the push rod and the piston.) This is done by turning the
push rod in or out.
• With the pedal travel set to the illustrated value, the push rod-to-
piston clearance should conform to the standard value.
• After the adjustment, tighten the lock nut to the specified torque.

Adjustment: Clearance between clutch switch and clutch

pedal
• With the clutch pedal adjusted as above, set the clearance be-
tween the end of the threaded portion of the clutch switch and
the pedal stopper to the value indicated in the drawing. Tighten
the lock nut.
CAUTION
• Do not allow the threaded end of the clutch switch to come
into contact with the clutch pedal stopper during the adjust-
ment operation.

21-16
CLUTCH MASTER CYLINDER 21
Disassembly sequence
1 Clevis
2 Circlip
3 Stop plate
4 Push rod
5 Piston
6 Union collar
7 O-ring
8 Cylinder body

: Non-reusable parts

Assembly sequence
Follow the disassembly sequence in re-
verse.

Repair kit: Clutch master cylinder kit

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
5, 8 Clearance between piston and cylinder body 0.02 to 0.1 0.2 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Lock nut 15 to 20 {1.5 to 2.0} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Push rod end contact face with piston
COSMO Rubber grease 0.1 to 0.3 g
Piston cup sliding face against cylinder body
Cylinder body inner face Metal rubber #20 (rust preventive oil) As required

Removal procedure
Removal: Piston
• With opening A blocked, feed compressed air gradually starting
from 0 kPa {0 kgf/cm2} to remove the piston.
WARNING
• Do not apply compressed air suddenly at high pressure.
Otherwise, the piston will fly out with full force.

21-17
CLUTCH PROPER

Removal sequence
1 Clutch cover
2 Clutch disc

*a: Flywheel
: Locating pin

Installation sequence
Follow the removal sequence in reverse.

CAUTION
• To prevent clutch slippage, keep the surfaces of the clutch cover, clutch disc and flywheel free from oil
and grease.

21-18
 21
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Pressure plate flatness – 0.05
1 Replace
Diaphragm spring finger height unevenness – 1.0
Depth from facing sur- C3 1.7 to 2.3 0.2
face to rivet C5 1.8 to 2.4 0.2
2 Clutch disc Play in revolving direction in splines 0.05 to 0.23 0.5 Replace
Vertical runout 1.0 or less 1.5
Lateral runout 0.8 or less 1.5

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Entire surface of splines Molybdenum disulfide grease 0.8 to 1.1 g
Fill in the grease grooves of splines [NLGI No. 2 (Li soap)] 3.2 to 4.2 g

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Clutch alignment arbor

<C3>
MH062954
Holding clutch disc
<C5>
MH061387
A B C
C3 φ17
φ28.94 120
C5 φ20

Sleeve
Checking diaphragm spring for in-
A B MH061425
stalled height
φ45 φ28.94

Plate
<C3>
A
MH061384 Checking diaphragm spring for in-
φ350 stalled height

Clutch master plate

<C5> Checking diaphragm spring for in-
A B C D MH062291 stalled hight
φ325 φ32 9.2 “5”

21-19
CLUTCH PROPER
Removal procedure
Removal: Clutch cover
• Insert into the flywheel pilot bearing. While supporting the
clutch disc with , remove the clutch cover.

Inspection procedure
Inspection: Clutch cover
(1) Pressure plate flatness
• Place a straight edge across the friction surface of the pressure
plate. Using a thickness gauge, measure the clearance between
the gauge and the surface in several locations selected random-
ly.
• Obtain the flatness of the pressure plate by subtracting the
smallest clearance measured from the greatest clearance mea-
sured.
• If the flatness is equal to or exceeds the specified limit, replace
the clutch cover.
(2) Inspection of diaphragm spring
• Inspect the diaphragm spring for play.
• If the spring has play, the clutch cover needs to be replaced.

(3) Inspection of installed height

<C3>
• Place on a surface plate. Then, install the clutch cover onto
.
• Install and onto the assembly. Using a thickness
gauge, measure the diaphragm spring finger for uneven height.
• If the unevenness is equal to or exceeds the limit, replace the
clutch cover.

<C5>
• Using , install (in place of the clutch disc) and the cluth
cover.
• Install and check for unevenness in height of the fingers using a
thickness gauge.
• If the unevenness exceeds the limit, replace the clutch cover.

21-20
 21
Inspection: Clutch disc
(1) Depth from facing surface to rivet
• Measure depth from the clutch disc facing surface to the rivet.
• If the measured value is equal to or less than the limit, replace
the clutch disc.

(2) Play in revolving direction in splines

• Reshape a thickness gauge such that it can be inserted into the
drive pinion splines. Then, using the gauge, measure the splines
for play in revolving direction.
• If the measured value is equal to or exceeds the limit, replace
the clutch disc.

Installation procedure
Installation: Clutch disc
• Insert into the flywheel pilot bearing to support the clutch
disc.
• Install the clutch cover by tightening the bolts diagonally and
gradually.

21-21
CLUTCH CONTROL

Removal sequence
1 Eye bolt 6 Bleeder cap
2 Clutch hose 7 Bleeder screw
3 Connector 8 Oil seal
4 Grommet 9 Dust plug <C5>
5 Clutch direct power cylinder 10 Clutch housing
(See later section.)

CAUTION
• When handling the clutch direct power cylinder, be careful not to smear it with mineral oil such as engine
oil and transmission oil. The smeared cylinder can cause brake fluid leakage.

Installation sequence
Follow the removal sequence in reverse.

21-22
 21
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Eye bolt (clutch hose mounting) 20 to 25 {2.0 to 2.5} –
Connector 33 to 49 {3.4 to 5.0} –
Bleeder screw 6.8 to 8.8 {0.7 to 0.9} –
Bolt (clutch direct power cylinder mounting) 44.5 {4.5} –
Nut (bleeder hose mounting) 51 to 60 {5.0 to 5.9} –
Bolt (clutch hose mounting) 45 to 55 {4.6 to 5.6} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Clutch direct power cylinder mating face with clutch
ThreeBond 1215 As required
housing
Wheel bearing grease
Oil seal lips As required
[NLGI No. 2 (Li soap)]

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Oil seal installer

Protecting oil seal during clutch direct
A MH063322
power cylinder installation
φ36.5

Oil seal installer

A MH062714 Oil seal installation

φ89

Installation procedure
Installation: Oil seal
• Apply grease onto the oil seal lips. Then, install the oil seal onto
the clutch direct power cylinder making sure that the seal faces
as shown in the drawing.

Installation: Clutch direct power cylinder

• After cleaning the sealant application surfaces, apply sealant as
required.
• Install onto the drive pinion to protect the oil seal previously
installed onto the clutch direct power cylinder.

21-23
CLUTCH CONTROL
Clutch Direct Power Cylinder

Disassembly sequence
1 Snap ring 10 Outer cup
2 Release bearing 11 Piston
3 Oil seal 12 Bleeder
4 Rear spring stopper 13 Rod
5 Front spring stopper 14 Cylinder body A
6 Boots 15 O-ring
7 Spring 16 Cylinder body B
8 Front inner cup
9 Rear inner cup : Non-reusable parts

CAUTION
• Remove the bleeder only when cylinder body A is being replaced. Because removing the bleeder may
cause the thread diformation of the cylinder body A. Therefore you must replace the cylinder body A
when removing the bleeder once. Reusing the body causes oil leak.

Assembly sequence
Follow the disassembly sequence in reverse.

CAUTION
• Install the piston correctly: It needs to be faced as shown in the drawing, and the cups should not be dis-
lodged. An incorrectly installed piston causes brake fluid leakage and clutch drag.

21-24
 21
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (cylinder bodies A, B and rod mounting) 6.8 to 8.8 {0.7 to 0.9} –
Bleeder hose 15.7 to 17.6 {1.6 to 1.8} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Front inner cup sliding face with cylinder body B COSMO Rubber grease 0.1 to 0.2 g
Cylinder body A sliding face
Metal rubber #20 (rust preventive oil) As required
Cylinder body B sliding face

Removal procedure
Removal: Piston
• With the bleeder hose fitting hole or opening of cylinder body A
blocked, feed compressed air gradually starting from 0 kPa {0
kgf/cm2} to remove the piston.
WARNING
• Do not apply compressed air suddenly at high pressure, or
the piston will fly out with full force.

Removal: Cylinder body A

• Install left-hand screws (M8 × 1.25 mm) evenly into the jacking
holes on cylinder body A and remove the body.

21-25
CLUTCH CONTROL
Installation procedure
Installation: Front inner cup, rear inner cup and outer cup
• Install the front inner cup, rear inner cup, and outer cup onto the
piston, facing them in the illustrated directions.
CAUTION
• Install the front inner cup, rear inner cup, and outer cup cor-
rectly, facing them in the illustrated directions. Incorrectly
installed cups cause brake fluid leakage and clutch drag.
• Do not apply grease onto the rear inner cup or the outer
cup. Otherwise, brake fluid will leak.
• Apply only a thin coat of grease to the front inner cup.
Greasing it too much can cause brake fluid leakage.

Installation: Front spring stopper

• Install the front spring stopper onto cylinder body A such that its
cutout aligns with the rod on the body and that it faces in the il-
lustrated direction.

Installation: Release bearing

• Install the release bearing onto cylinder body B such that its
flange or wear limit switch plate aligns with the rod on cylinder
body A and that it faces in the illustrated direction.

21-26