Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Mitsubishi Eclipse & Spyder 2000-2006 Approved Mitsubishi Eclipse & Spyder 2003-2005 GR00001900-21A
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21A-1
GROUP 21A
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 21A-2 CLUTCH PEDAL. . . . . . . . . . . . . . . . . 21A-10
CLUTCH PEDAL REMOVAL AND
CLUTCH DIAGNOSIS . . . . . . . . . . . . 21A-2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21A-10
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 21A-2 CLUTCH PEDAL INSPECTION . . . . . . . . . 21A-10
TROUBLESHOOTING STRATEGY . . . . . . 21A-2
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 21A-3 CLUTCH CONTROL . . . . . . . . . . . . . . 21A-11
SYMPTOM PROCEDURES . . . . . . . . . . . . 21A-3 CLUTCH CONTROL REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21A-11
ON-VEHICLE SERVICE. . . . . . . . . . . 21A-7 CLUTCH CONTROL INSPECTION. . . . . . . 21A-12
CLUTCH MASTER CYLINDER
CLUTCH PEDAL CHECK AND
ASSEMBLY DISASSEMBLY AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-7
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21A-13
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-8
CLUTCH MASTER ASSEMBLY
CLUTCH PEDAL POSITION SWITCH CYLINDER INSPECTION . . . . . . . . . . . . . . 21A-14
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A-8
INTERLOCK SWITCH OPERATING
SPECIFICATIONS . . . . . . . . . . . . . . . 21A-14
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A-8
FASTENER TIGHTENING
INTERLOCK SWITCH CHECK AND
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 21A-14
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-9
GENERAL SPECIFICATION . . . . . . . . . . . . 21A-14
SERVICE SPECIFICATIONS . . . . . . . . . . . 21A-14
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 21A-14
21A-2 CLUTCH
GENERAL DESCRIPTION
.
GENERAL DESCRIPTION
M1211000100115
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
CONSTRUCTION DIAGRAM
RESERVOIR TANK
RESERVOIR HOSE PEDAL SUPORT
MEMBER
CLUTCH TUBE
CLUTCH HOSE
CLUTCH TUBE
CLUTCH MASTER
CLUTCH RELEASE
CYLINDER
CYLINDER
DAMPER ASSEMBLY
<3.0L ENGINE>
STOPPER
CLUTCH PEDAL
AC001238AB
CLUTCH DIAGNOSIS
INTRODUCTION TO CLUTCH DIAGNOSIS
M1211003400115
A defective clutch causes a clutch slippage, resulting
in poor torque transmission. The causes for this
problem may be a faulty clutch line or disc, or a mal-
adjustment of the clutch pedal.
CLUTCH DIAGNOSIS TROUBLESHOOTING STRATEGY
M1211003500101
Use these Steps to plan your diagnostic strategy. If 2. Verify that the condition described by the cus-
you follow them carefully, you will be sure that you tomer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
clutch fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
TSB Revision
CLUTCH
CLUTCH DIAGNOSIS
21A-3
SYMPTOM CHART
M1211003600090
SYMPTOMS INSPECTION REFERENCE PAGE
PROCEDURE
Clutch slips 1 P.21A-3
Gear shift malfunction 2 P.21A-4
Clutch noise 3 P.21A-4
Clutch pedal feels "heavy" 4 P.21A-5
When the clutch is engaged, abnormal vibration occurs. 5 P.21A-6
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Clutch Slips
DIAGNOSIS Step 4. Check the clutch disc facing for
excessive wear.
Step 1. Check insufficient clutch pedal play. Refer to GROUP 21B, Clutch P.21B-6.
Refer to P.21A-7. Q: Is the clutch disc facing worn excessively?
Q: Does the clutch pedal play meet the standard YES : Replace the clutch disc. Then go to Step 7.
value? NO : Go to Step 5.
YES : Go to Step 2.
NO : Adjust the clutch pedal play. Then go to
Step 5. Check the clutch disc facing for
Step 7.
hardening and adhesion of oil.
Refer to GROUP 21B, Clutch P.21B-6.
Step 2. Check the hydraulic system for clogging.
Q: Is the clutch disc facing hardened or contaminated
Q: Is the hydraulic system clogged? with oil?
YES : Repair or replace the hydraulic system. YES : Replace the clutch disc. Then go to Step 7.
Then go to Step 7. NO : Go to Step 6.
NO : Go to Step 3.
Step 6. Check the diaphragm spring for
Step 3. Check the clutch release fork for weakness and damage.
catching. Refer to GROUP 21B, Clutch P.21B-6.
Q: Is the clutch release fork stuck? Q: Is the diaphragm spring weaken or damaged?
YES : Repair or replace the clutch release fork. YES : Replace the clutch cover assembly. Then
Then go to Step 7. go to Step 7.
NO : Go to Step 4. NO : Go to Step 7.
Step 7. Check the symptom.
Q: Is the symptom reproduced?
YES : Return to Step 1.
NO : This diagnosis is complete.
TSB Revision
21A-4 CLUTCH
CLUTCH DIAGNOSIS
INSPECTION PROCEDURE 2: Gear Shift Malfunction
DIAGNOSIS Step 5. Check the clutch disc facing for peeling.
Q: Is clutch disc facing peeled?
Step 1. Check the excessive clutch pedal play. YES : Replace the clutch disc. Then go to Step 9.
Refer to P.21A-7. NO : Go to Step 6.
Q: Does the clutch pedal play meet the standard
value? Step 6. Check the clutch cover assembly for
YES : Go to Step 2.
wear.
NO : Adjust the clutch pedal play. Then go to
Refer to GROUP 21B, Clutch P.21B-6.
Step 9.
Q: Is the clutch cover assembly worn?
YES : Replace the clutch cover assembly. Then
Step 2. Check the hydraulic system for leakage, go to Step 9.
air mix and clogging. NO : Go to Step 7.
Refer to P.21A-11.
Q: Is there a leakage, air mix or clogging on the Step 7. Check the pressure plate and the flywheel
hydraulic system?
for damage.
YES : Repair or replace the hydraulic system.
Then go to Step 9. Q: Is the pressure plate or the flywheel damaged?
NO : Go to Step 3. YES : Replace the clutch cover assembly or the
flywheel. Then go to Step 9.
NO : Go to Step 8.
Step 3. Check the clutch disc for distortion and
excessive oscillation.
Refer to GROUP 21B, Clutch P.21B-6. Step 8. Check the clutch release bearing for wear.
Refer to GROUP 21B, Clutch P.21B-6.
Q: Is the clutch disc distorted or oscillated?
YES : Replace the clutch disc. Then go to Step 9. Q: Is the clutch release bearing worn?
NO : Go to Step 4. YES : Replace the clutch release bearing. Then
go to Step 9.
NO : Go to Step 9.
Step 4. Check the clutch disc spline for wear and
corrosion.
Refer to GROUP 21B, Clutch P.21B-6. Step 9. Check the symptom.
Q: Is the clutch disc spline worn or corroded? Q: Is the symptom reproduced?
YES : Replace the clutch disc. Then go to Step 9. YES : Return to Step 1.
NO : Go to Step 5. NO : This diagnosis is complete.
INSPECTION PROCEDURE 3: Clutch Noise
DIAGNOSIS Step 2. Check the clutch release bearing for wear.
Refer to GROUP 21B, Clutch P.21B-6.
Step 1. Check insufficient clutch pedal play. Q: Is the clutch release bearing worn?
Refer to P.21A-7. YES : Replace the clutch release bearing. Then
Q: Does the clutch pedal play meet the standard go to Step 7.
value? NO : Go to Step 3.
YES : Go to Step 2.
NO : Adjust the clutch pedal play. Then go to
Step 7.
TSB Revision
CLUTCH
CLUTCH DIAGNOSIS
21A-5
Step 3. Check the bearing sleeve sliding surface Step 5. Check the clutch disc facing for
for insufficient lubrication. excessive wear.
Q: Is the lubrication of the bearing sleeve sliding
Refer to GROUP 21B, Clutch P.21B-6.
surface sufficient? Q: Is the clutch disc facing assembly worn
YES : Go to Step 4. excessively?
NO : Repair the bearing sleeve sliding surface. YES : Replace the clutch disc. Then go to Step 7.
Then go to Step 7. NO : Go to Step 6.
Step 4. Check the clutch cover assembly for Step 6. Check the pilot bushing for damage.
improper installation. Q: Is the pilot bushing damaged?
Refer to GROUP 21B, Clutch P.21B-2. YES : Replace the pilot bushing. Then go to Step
Q: Is the clutch cover assembly installed properly? 7.
YES : Go to Step 5. NO : Go to Step 7.
NO : Install the clutch cover assembly properly.
Then go to Step 7. Step 7. Check the symptom.
Q: Is the symptom reproduced?
YES : Return to Step 1.
NO : This diagnosis is complete.
INSPECTION PROCEDURE 4: Clutch Pedal Feels "Heavy"
DIAGNOSIS Step 3. Check the insufficient lubrication of
bearing sleeve sliding surface.
Step 1. Check the clutch pedal clevis pin for Q: Is the lubrication of the bearing sleeve sliding
insufficient lubrication. surface sufficient?
Q: Is the lubrication of the clutch pedal clevis pin YES : Go to Step 4.
sufficient? NO : Repair the bearing sleeve sliding surface.
YES : Go to Step 2. Then go to Step 4.
NO : Repair the clutch pedal. Then go to Step 4.
Step 4. Check the symptom.
Step 2. Check the clutch disc spline for Q: Is the symptom reproduced?
insufficient lubrication. YES : Return to Step 1.
Refer to GROUP 21B, Clutch P.21B-6. NO : This diagnosis is complete.
Q: Is the lubrication of the clutch disc spline
sufficient?
YES : Go to Step 3.
NO : Replace the clutch disc. Then go to Step 4.
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21A-6 CLUTCH
CLUTCH DIAGNOSIS
INSPECTION PROCEDURE 5: When the Clutch is Engaged, Abnormal Vibration Occurs.
.
DIAGNOSIS Step 4. Check the clutch disc facing for wear and
damage.
Step 1. Check the engine and transaxle mounting Refer to GROUP 21B, Clutch P.21B-6.
for loosening and damage. Q: Is the clutch disc facing worn or damaged?
YES : Replace the clutch disc. Then go to Step 6.
Q: Is the engine and transaxle mounting loosened or
NO : Go to Step 5.
damaged?
YES : Tighten or replace the engine and transaxle
mounting. Then go to Step 6. Step 5. Check for grease or oil on the clutch disc
NO : Go to Step 2. facing.
Refer to GROUP 21B, Clutch P.21B-6.
Step 2. Check the diaphragm spring for uneven Q: Is there grease or oil on the clutch disc facing?
height. YES : If the clutch disc facing is contaminated with
Q: Is the diaphragm spring even height?
grease or oil, check that greases is applied
YES : Go to Step 3. to the clutch disc spline. (Refer to GROUP
NO : Replace the clutch cover assembly. Then go 21B, Clutch P.21B-2.) Then check the
to Step 6. clutch housing input shaft oil seal (Refer to
GROUP 22B, Clutch Housing P.22B-56.)
and the crank shaft rear oil seal (2.4L
Step 3. Check the pressure plate and flywheel for ENGINE: Refer to GROUP 11A, Crankshaft
damage. Rear Oil Seal P.11A-26, 3.0L ENGINE:
Q: Is the pressure plate or flywheel damaged? Refer to GROUP 11C, Crankshaft Rear Oil
YES : Repair the clutch cover assembly or Seal P.11C-32.) for leakage, and replace
flywheel. Then go to Step 6. the oil seal(s). Replace the clutch disc. Then
NO : Go to Step 4. go to Step 6.
NO : Go to Step 6.
Step 6. Check the symptom.
Q: Is the symptom reproduced?
YES : Return to Step 1.
NO : This diagnosis is complete.
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CLUTCH
ON-VEHICLE SERVICE
21A-7
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND ADJUSTMENT
M1211000900111
1. Turn back the carpet etc. under the clutch pedal.
2. Measure the clutch pedal height. If the height is outside the
CLUTCH PEDAL CLUTCH PEDAL
HEIGHT CLEVIS PIN PLAY standard value, go to step 4.
Standard value (A): 175.3 - 178.3 mm (6.90 - 7.02
inches) [From the surface of melting sheet (Floor
board shield) to the face of pedal pad]
3. Measure the clutch pedal clevis pin play. If the play is
A B outside the standard value, go to step 5.
Standard value (B): 1 - 3 mm (0.04 - 0.12 inch)
AC001133AB
4. If the height of the clutch pedal is not within the standard
value, loosen the locking nut and adjust the pedal height to
LOCKING NUT the standard value using the adjusting bolt or push rod.
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