Clutch Master Cylinder 7 - . - . - . - . - . - . - . - . - . - . - . .

21-1
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Inspection and Adjustment . . . . . . . . 2
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7
21-2
CLUTCH
General Information/Service Specifications/Lubricants/On-vehicle Service
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
Items
Standard value
Clutch pedal height mm
212 215 <L.H. drive vehicles>

202 205 <R.H. drive vehicles>
Clutch pedal clevis pin play mm
13
Clutch pedal free play mm
6 13
Distance between the clutch pedal and the toeboard

when the clutch is disengaged mm
110 or more
LUBRICANTS
Items
Specified lubricants
Quantity
Clutch fluid
Brake fluid DOT3 or DOT4
As required
Push rod assembly
Rubber grease
Release cylinder push rod
MITSUBISHI genuine grease

Part No. 0101011
Clutch pedal height
Clutch pedal clevis

pin play
ON-VEHICLE SERVICE
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.

2. Measure the clutch pedal height and the clutch pedal clevis
pin play.
Standard value (A):
212 215 <L.H. drive vehicles>
202 205 <R.H. drive vehicles>
Standard value (B): 1 3 mm
CLUTCH On-vehicle Service
21-3
3. If the clutch pedal height and the clutch pedal clevis pin
play are outside the standard value, turn the setting nut
to adjust them to the standard value.
Setting nut
Caution
Do not push in the master cylinder push rod at this
time, otherwise the clutch will not operate properly.
Clutch pedal
12 Nm
Clutch pedal free

play
Distance between the

clutch pedal and the
toeboard when the
clutch is disengaged
4. 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 toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6 13 mm
Standard value (D): 110 mm or more
5. If the clutch pedal free play and the distance between
the clutch pedal and the toeboard 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, release cylinder or clutch. Bleed
the air, or disassemble and inspect the master cylinder,
release cylinder or clutch.
6. Turn back the carpet, etc.
BLEEDING
Clutch release cylinder
Specified fluid: Brake fluid DOT 3 or DOT 4

Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
21-4
CLUTCH Clutch Pedal
CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21-2.)
L.H. drive vehicles
R.H. drive vehicles
12 Nm
12 Nm
4
1
12 Nm
12 Nm
7
6
5
Removal steps
1. Snap pin
2. Clevis pin
3. Clutch master cylinder mounting nut
4. Master cylinder member mounting bolt
5. Stopper <R.H. drive vehicles>

6. Pedal pad
7. Clutch pedal assembly
21-5
CLUTCH Clutch Control
CLUTCH CONTROL
REMOVAL AND INSTALLATION
Pre-removal Operation
Clutch Fluid Draining
Post-installation Operation
D Clutch Fluid Supplying
D Clutch Line Bleeding (Refer to P.21-3.)
D Clutch Pedal Adjustment (Refer to P.21-2.)
<L.H. drive vehicles>
13 Nm
Release fork
Release cylinder
push rod
13
7
5 Nm
5
3
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
4
11
19 Nm
15 Nm
10
12 Nm
12
11, 13
9
13
20 25 Nm
5 Nm
12 Nm
Clutch master cylinder assembly

removal steps
1. Clevis pin
2. Clutch pipe connection
3. Breather hose connection
4. Clutch master cylinder assembly
5. Sealer
Reservoir tank removal steps
3. Breather hose connection
5. Bolt
6. Reservoir bracket
7. Reservoir tank
8. Breather hose
Clutch release cylinder assembly
removal steps
10. Clutch release cylinder assembly
Clutch line removal steps
11. Clutch pipe
12. Bracket
13. Clutch hose
21-6
<R.H. drive vehicles>

1
2
Release
cylinder
push rod
Release fork
7
3
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
12 Nm
7
19 Nm
15 Nm
6
8
5
9
12 Nm
5 Nm
Clutch master cylinder assembly

removal steps
1. Clevis pin
3. Clutch master cylinder assembly
4. Sealer
20 25 Nm
Clutch release cylinder assembly

removal steps
6. Clutch release cylinder assembly
Clutch line removal steps
7. Clutch pipe
8. Bracket
9. Clutch hose
21-7

DISASSEMBLY AND REASSEMBLY
CLUTCH MASTER CYLINDER
Caution
Do not disassemble piston assembly.
6
12 Nm
8
9
5
9
3
4
1
7
2
7
10
11
2
2
3
Piston repair kit
Clutch fluid:
Brake fluid DOT3 or DOT4
Disassembly steps
1. Piston stopper ring
2. Piston assembly
"AA 3. Push rod assembly
4. Boot
5. Nipple <L.H. drive vehicles>
6. Reservoir cap <R.H. drive vehicles>
7. Spring pin
Grease: Rubber grease
8. Reservoir tank <R.H. drive vehicles>

9. Seal
10. Master cylinder body <L.H. drive
vehicles>
11. Master cylinder body <R.H. drive
vehicles>
INSTALLATION SERVICE POINT

"AA PUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown dimension
to make the adjustment of clutch pedal easier.
<L.H. drive vehicles> 103 mm
<R.H. drive vehicles> 126 mm
NOTES

Clutch Master Cylinder 7 - . - . - . - . - . - . - . - . - . - . - . .

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21-1

Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 7

General Information/Service Specifications/Lubricants/On-vehicle Service

Clutch pedal height mm

212 215 <L.H. drive vehicles>

Clutch pedal clevis pin play mm

Clutch pedal free play mm

Distance between the clutch pedal and the toeboard

Brake fluid DOT3 or DOT4

Push rod assembly

Release cylinder push rod

MITSUBISHI genuine grease

Clutch pedal height

Clutch pedal clevis

1. Turn up the carpet, etc. under the clutch pedal.

CLUTCH On-vehicle Service

Clutch pedal free

Distance between the

4. After completing the adjustments, confirm that the clutch

Specified fluid: Brake fluid DOT 3 or DOT 4

CLUTCH Clutch Pedal

L.H. drive vehicles

R.H. drive vehicles

5. Stopper <R.H. drive vehicles>

CLUTCH Clutch Control

<L.H. drive vehicles>

Clutch master cylinder assembly

CLUTCH Clutch Control

<R.H. drive vehicles>

Clutch master cylinder assembly

Clutch release cylinder assembly

CLUTCH Clutch Control

Piston repair kit

Grease: Rubber grease

8. Reservoir tank <R.H. drive vehicles>

INSTALLATION SERVICE POINT

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