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Tim's Auto Repair
Tim's Auto Repair, Mechanic
Category: Car
Satisfied Customers: 12787
Experience:  Have owned a repair shop for 25 yrs.
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amigo: I have an Isuzu Amigo which I installed a new clutch

Resolved Question:

I have an Isuzu Amigo which I installed a new clutch set in and Ican not get the throw out bearing to travel in the correct direction when the slave cylinder is engaged. when i got the car everything was broken in the throwout bearing and its linkage so i do not know if i am missing something or i am installing something incorrect. any info would be greatly appreciated. thank you Jeff
Submitted: 1 year ago.
Category: Car
Expert:  Tim's Auto Repair replied 1 year ago.

tims auto repair :

hi


 

tims auto repair :

what engine do you have?


 

tims auto repair :

is it a 4wd or 2wd?


 

Customer:

3.2 v-6 4wd

tims auto repair :

ok


 

tims auto repair :

when you press the pedal...the bearing gos bckwards?


 

tims auto repair :

backwards?


 

Customer:

correct away from the pressure plate

tims auto repair :

strange indeed


 

tims auto repair :

it the slave pushing out?


 

Customer:

yeah i got another fork n it is the same as the one that was in the amigo

tims auto repair :

i see


 

Customer:

yes but it then pushes the bearing away from the p-p

tims auto repair :

if it is pushing out


 

tims auto repair :

it should push it away..it would haf to release the clutch


 

Customer:

?

tims auto repair :

the slave pushes out correct?when you press the pedal?


 

tims auto repair :

when you press the pedal...the slave extends?


 

Customer:

it travels just like a master cyl would n previous owner said it was just replaced

tims auto repair :

there is surley something wrong there


 

tims auto repair :

i will give you some pictures here


 

tims auto repair :




























1999 Isuzu Truck Amigo 4WD V6-3.2L
Clutch Slave Cylinder Service and Repair, Procedures: Clutch Controls/Removal/Installation/Adjustment









28_sz98rodeo_7c-026a.png
Full Size Image



PARTS LOCATION VIEW


REMOVAL
1. Disconnect the ground battery cable.








40_hn01passp_7c-024a.png
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2. Remove the instrument panel lower cover (7) and driver knee bolster panel assembly (8).
3. Remove pin and jaw joint pin (1).
4. Remove pedal assembly and switch (2).
5. Remove oil line pipe (3).
6. Remove slave cylinder assembly (4).








22_sz98rodeo_7c-027b.png
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MUA (4x2)








23_sz98rodeo_7c-027c.png
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B.W T5R

7. Remove master cylinder assembly (5).
8. Remove oil line hose (6).

INSPECTION AND REPAIR
Make necessary adjustments, repairs, and part replacements if wear, damage or other problems are discovered during inspection.


INSTALLATION
CLUTCH PEDAL ADJUSTMENT








30_sz98rodeo_7c-028a.png
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1. With clutch switch.
1. Disconnect clutch switch connector.
2. Loosen lock nut, then turn switch out until there is a gap between the switch plunger and clutch pedal.








58_hn01passp_7c-025a.png
Full Size Image



2. Loosen clutch master cylinder push rod lock nut. Turn push rod by hand to set clutch pedal height to within specification. Tighten push rod lock nut.

Clutch Pedal Height: 178 - 188 mm (7.01 - 7.40 inch)








31_sz98rodeo_7c-028c.png
Full Size Image



3. With clutch switch.
1. Turn the clutch switch until the switch bolt just touches the clutch pedal arm.
2. Adjust clutch switch by backing it out half a turn, and measure the clearance between the clutch pedal arm and the clutch switch bolt end.
3. Lock the lock nut.
4. Connect clutch switch connector.

Clutch Switch and Clutch Pedal Clearance: 0.5 - 1.5 mm (0.020 - 0.059 inch)

4. After adjusting the clutch pedal height, push the clutch pedal by hand to ensure the clutch pedal free play is within specification.

Pedal Free Play: 5 - 15 mm (0.20 - 0.59 inch)

5. Perform clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the wheels.
2. Start the engine, fully step on the clutch pedal slowly and move the shift lever 1st position.
3. With the engine idling, release the clutch pedal slowly and measure its stroke - just prior to its clutching position.








63_hn01passp_7c-025c.png
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Clutch Pedal Engagement Height (H3): MIN. 30 mm (1.18 inch)


6. If the measured value exceeds the specified limit, check the following points and repair if necessary:
- Hydraulic circuit for fluid leakage or air in circuit.
- Clutch disc warped.
- Diaphragm spring weakened or tip of fingers worn.
- Driven plate sticking on splines.
- Release bearing worn or damaged.
- Master cylinder and slave cylinder worn.

Torque
- Master cylinder to dash panel: 16 Nm (12 ft. lbs.)
- Clutch pedal to dash panel: 15 Nm (11 ft. lbs.)
- Master cylinder push rod to yoke: 17 Nm (12 ft. lbs.)
- Clutch pipe to master cylinder: 20 Nm (14 ft. lbs.)
- Clutch pipe to flex, hose: 20 Nm (14 ft. lbs.)
- Slave cylinder to case: 43 Nm (32 ft. lbs.)
- Slave cylinder bleeder screw: 8 Nm (69 inch lbs.)
- Clutch pipe to slave cylinder: 20 Nm (14 ft. lbs.)


 

tims auto repair :




























1999 Isuzu Truck Amigo 4WD V6-3.2L
Clutch Service and Repair, Procedures: Unit Overhaul









24_sz98rodeo_7c-018a.png
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CLUTCH ASSEMBLY (V6, MUA) AND ASSOCIATED PARTS

REMOVAL

1. Remove transmission assembly (1).








32_hn01passp_7c-016a.png
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2. Use the pilot aligner J24547 to prevent the driven plate assembly (3) from falling free.
3. Mark the flywheel, clutch cover and pressure plate lug for alignment when installing.








91_hn01passp_7c-016b.png
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4. Remove the release bearing (4) from the transmission case.








93_hn01passp_7c-016c.png
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5. Remove the snap pin. Remove the shift fork pin and shift fork from the fulcrum bridge.








96_hn01passp_7c-016d.png
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6. Remove the fulcrum bridge bolts. Remove the fulcrum bridge (6) from the transmission case.
- Do not remove crankshaft bearing (7) except for replacement.








00_hn01passp_7c-017a.png
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- Use the remover J-5822 and sliding hammer J-23907 to remove the crankshaft bearing.

INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage, or any other abnormal condition are found through inspection.

Pressure Plate Assembly








02_hn01passp_7c-017b.png
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- Visually check the pressure plate friction surface for excessive wear and heat cracks. If excessive wear or deep heat cracks are present, the pressure plate must be replaced.

Pressure Plate Warpage








04_hn01passp_7c-017c.png
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- Use a straight edge and a feeler gauge to measure the pressure plate friction surface flatness in four directions. If any of the measured values exceed the specified limit, the pressure plate must be replaced.

Limit: 0.3 mm (0.012 inch)

Clutch Cover








07_hn01passp_7c-017d.png
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- Visually check the entire clutch cover for excessive wear, cracking, and other damage. The clutch cover must be replaced if any of these conditions are present.


Clutch Set Force
1. Invert the pressure plate assembly.








09_hn01passp_7c-018a.png
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2. Place a new driven plate over the pressure plate. A metal sheet with thickness of 8.0 mm (0.315 inch) may be used in place of the driven plate.
3. Compress the pressure plate assembly until the distance becomes 12 mm (0.472 inch).
4. Note the pressure gauge reading. If the measured value is less than the specified limit, the pressure plate assembly must be replaced.

Clutch Set Force
Standard: 7208 N (1621 lbs.)
Limit: 6669 N (1499 lbs.)

Diaphragm Spring Finger Height
1. Place a new driven plate or a 8.0 mm (0.315 inch) spacer beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm spring.
There are two ways to do this:
a. Use a bench press to press down on the assembly from the top.
b. Tighten the fixing bolts.

NOTE: Preload on diaphragm spring finger must be 4998 N (11-22 lbs.) in direction of release, when clutch cover assembly is bolted to the flywheel.








33_hn01passp_7c-018b.png
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3. Measure the spring height from base to spring tip. If the measured value exceeds the specified limit, the pressure plate assembly must be replaced.

Standard: 49.9 - 51.9 mm (1.965 - 2.043 inch)

Driven Plate Assembly








29_hn01passp_7c-011c.png
Full Size Image



- Visually check the torsion spring for looseness, breakage, and weakening. If any of these conditions are discovered, the driven plate assembly must be replaced.
- Visually check the facing surfaces for cracking and excessive scorching. Visually inspect the facing surfaces for the presence of oil or grease. If any of these conditions are discovered, the facing must be cleaned or replaced.
- Check that the driven plate moves smoothly on the transmission top gear shaft spline. Minor ridges on the top gear shaft spline may be removed with an oil stone.


Driven Plate Warpage
1. Insert the clutch pilot aligner J-24547 into the driven plate splined hub. The clutch pilot aligner must be held perfectly horizontal.
2. Set a dial indicator to the driven plate outside circumference.








65_hn01passp_7c-011d.png
Full Size Image



3. Slowly turn the driven plate. Read the dial indicator as you turn the driven plate. If the measured value exceeds the specified limit, the driven plate assembly must be replaced.

Driven Plate Warpage
Standard: 0.7 mm (0.028 inch)
Limit: 1.0 mm (0.039 inch)

Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft spline.
3. Set a surface gauge to the driven plate outside circumference.








66_hn01passp_7c-012a.png
Full Size Image



4. Slowly turn the driven plate counterclockwise. Measure the spline rotation play as you turn the driven plate. If the measured value exceeds the specified limit, the driven plate assembly must be replaced.

Driven Plate Warpage
Standard: 0.5 mm (0.020inch)
Limit: 1.0 mm (0.039 inch)


Rivet Head Depression








68_hn01passp_7c-012b.png
Full Size Image



- Use a depth gauge or a straight edge with steel rule to measure the rivet head depression (1) from the facing surface (2).
- Be sure to measure the rivet head depression on both sides of the driven plate. If the measured value is less than the specified limit, the driven plate assembly must be replaced.








07_sz98rodeo_7c-022c.png
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Rivet Head Depression


Release Bearing








35_hn01passp_7c-020a.png
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- Visually check the release bearing for excessive play, noise and breakage. If any of these conditions are discovered, the release bearing must be replaced.








36_hn01passp_7c-020b.png
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- When replacing the release bearing (4), replace both the wedge collar (10) and wire ring (11) at the same time.

Wedge Collar (10)








37_hn01passp_7c-020c.png
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- Visually check the surfaces of the wedge collar making contact with the release bearing for excessive wear and damage.
- Replace exhibiting excessive wear or damage.

Shift Fork








31_hn01passp_7c-020d.png
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- Visually check the surfaces of the shift fork making contact with the release bearing for excessive wear and damage.
- Remove any minor stepping or abrasion from shift fork with an oil stone. Replace exhibiting excessive wear or damage.


INSTALLATION
1. Clean and lubricate with grease.








34_hn01passp_7c-021a.png
Full Size Image



2. Use the installer J-26516-A and driver handle J-8092 to install the crankshaft bearing (7).








96_hn01passp_7c-016d.png
Full Size Image



3. Install the fulcrum bridge (6) to the transmission case. Tighten three fulcrum bridge bolts to the specified torque.

Torque: 38 Nm (28 Ft. lbs.)








39_hn01passp_7c-021c.png
Full Size Image



4. Apply molybdenum disulfide type grease to the pin hole inner circumferences and thrust surfaces. Attach the shift fork (5) to the fulcrum bridge (6) and insert the pin from below of the fulcrum bridge. Install the washer and snap pin.








83_hn97passp_7c-021b.png
Full Size Image



5. Apply molybdenum disulfide type grease to the areas shown in the figure.
Install the release bearing (4) in the proper direction.








43_hn01passp_7c-022a.png
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NOTE: Ensure release bearing is properly positioned during installation, as shown in the figure.








46_hn01passp_7c-022b.png
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6. Use the pilot aligner -24547 to install the driven plate assembly (3).








48_hn01passp_7c-022c.png
Full Size Image



7. Tighten the bolts holding the pressure plate assembly (2) in the order shown in the figure.

Torque: 18 Nm (13 Ft. lbs.)

8. Remove the aligner.

NOTE: Do not strike the aligner with a hammer to remove it.

9. Install transmission assembly to the engine.

tims auto repair :

 

tims auto repair :

if everything is installed this way......it can not move backwards


 

Customer:

i am still looking at pictures and reading directions

tims auto repair :

ok


 

tims auto repair :

i will be on and off here all da


y...take your time

tims auto repair :

 

Customer:

do you have any diagrams of the slave cylinder and its linkage to the release bearing fork? thank you

tims auto repair :

hi


 

tims auto repair :




























1999 Isuzu Truck Amigo 4WD V6-3.2L
Clutch Slave Cylinder Service and Repair, Procedures: Clutch Controls/Removal/Installation/Adjustment









28_sz98rodeo_7c-026a.png
Full Size Image



PARTS LOCATION VIEW


REMOVAL
1. Disconnect the ground battery cable.








40_hn01passp_7c-024a.png
Full Size Image



2. Remove the instrument panel lower cover (7) and driver knee bolster panel assembly (8).
3. Remove pin and jaw joint pin (1).
4. Remove pedal assembly and switch (2).
5. Remove oil line pipe (3).
6. Remove slave cylinder assembly (4).








22_sz98rodeo_7c-027b.png
Full Size Image



MUA (4x2)








23_sz98rodeo_7c-027c.png
Full Size Image



B.W T5R

7. Remove master cylinder assembly (5).
8. Remove oil line hose (6).

INSPECTION AND REPAIR
Make necessary adjustments, repairs, and part replacements if wear, damage or other problems are discovered during inspection.


INSTALLATION
CLUTCH PEDAL ADJUSTMENT








30_sz98rodeo_7c-028a.png
Full Size Image



1. With clutch switch.
1. Disconnect clutch switch connector.
2. Loosen lock nut, then turn switch out until there is a gap between the switch plunger and clutch pedal.








58_hn01passp_7c-025a.png
Full Size Image



2. Loosen clutch master cylinder push rod lock nut. Turn push rod by hand to set clutch pedal height to within specification. Tighten push rod lock nut.

Clutch Pedal Height: 178 - 188 mm (7.01 - 7.40 inch)








31_sz98rodeo_7c-028c.png
Full Size Image



3. With clutch switch.
1. Turn the clutch switch until the switch bolt just touches the clutch pedal arm.
2. Adjust clutch switch by backing it out half a turn, and measure the clearance between the clutch pedal arm and the clutch switch bolt end.
3. Lock the lock nut.
4. Connect clutch switch connector.

Clutch Switch and Clutch Pedal Clearance: 0.5 - 1.5 mm (0.020 - 0.059 inch)

4. After adjusting the clutch pedal height, push the clutch pedal by hand to ensure the clutch pedal free play is within specification.

Pedal Free Play: 5 - 15 mm (0.20 - 0.59 inch)

5. Perform clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the wheels.
2. Start the engine, fully step on the clutch pedal slowly and move the shift lever 1st position.
3. With the engine idling, release the clutch pedal slowly and measure its stroke - just prior to its clutching position.








63_hn01passp_7c-025c.png
Full Size Image



Clutch Pedal Engagement Height (H3): MIN. 30 mm (1.18 inch)


6. If the measured value exceeds the specified limit, check the following points and repair if necessary:
- Hydraulic circuit for fluid leakage or air in circuit.
- Clutch disc warped.
- Diaphragm spring weakened or tip of fingers worn.
- Driven plate sticking on splines.
- Release bearing worn or damaged.
- Master cylinder and slave cylinder worn.

Torque
- Master cylinder to dash panel: 16 Nm (12 ft. lbs.)
- Clutch pedal to dash panel: 15 Nm (11 ft. lbs.)
- Master cylinder push rod to yoke: 17 Nm (12 ft. lbs.)
- Clutch pipe to master cylinder: 20 Nm (14 ft. lbs.)
- Clutch pipe to flex, hose: 20 Nm (14 ft. lbs.)
- Slave cylinder to case: 43 Nm (32 ft. lbs.)
- Slave cylinder bleeder screw: 8 Nm (69 inch lbs.)
- Clutch pipe to slave cylinder: 20 Nm (14 ft. lbs.)


 

Customer:

When the petal is pushed in does that rig on the throw out bearing pull out the diapham or push it in


 


 


 


 

tims auto repair :

when the pedal is pushed in.....the slave cylender pushes out[extends] this pushes the fork,that push


es the through out bearing toward the pressure plate

tims auto repair :

 

Tim's Auto Repair, Mechanic
Category: Car
Satisfied Customers: 12787
Experience: Have owned a repair shop for 25 yrs.
Tim's Auto Repair and 12 other Car Specialists are ready to help you

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