Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Mitsubishi Eclipse & Spyder 2000-2006 Approved Mitsubishi Eclipse 2006 GR00003400-21A
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21A-1
GROUP 21A
CLUTCH
CONTENTS
GENERAL DESCRIPTION. . . . . . . . . 21A-2 CLUTCH INTERLOCK SWITCH CHECK
AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 21A-11
CLUTCH DIAGNOSIS . . . . . . . . . . . . 21A-3
INTRODUCTION TO CLUTCH
CLUTCH PEDAL. . . . . . . . . . . . . . . . . 21A-12
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 21A-3 REMOVAL AND INSTALLATION . . . . . . . . 21A-12
CLUTCH DIAGNOSIS INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-13
TROUBLESHOOTING STRATEGY . . . . . . 21A-3
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 21A-3 CLUTCH CONTROL . . . . . . . . . . . . . . 21A-13
SYMPTOM PROCEDURES . . . . . . . . . . . . 21A-3 REMOVAL AND INSTALLATION . . . . . . . . 21A-13
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-16
ON-VEHICLE SERVICE. . . . . . . . . . . 21A-9 CLUTCH MASTER CYLINDER . . . . . . . . . . 21A-17
CLUTCH PEDAL CHECK AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 21A-18
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21A-9
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . 21A-10 SPECIFICATIONS . . . . . . . . . . . . . . . 21A-19
CLUTCH PEDAL POSITION SWITCH FASTENER TIGHTENING
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A-10 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 21A-19
CLUTCH INTERLOCK SWITCH OPERATING GENERAL SPECIFICATION . . . . . . . . . . . . 21A-19
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A-10
SERVICE SPECIFICATIONS . . . . . . . . . . . 21A-19
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . 21A-19
21A-2 CLUTCH
GENERAL DESCRIPTION
GENERAL DESCRIPTION
M1211000100289
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
CONSTRUCTION DIAGRAM
<5M/T> RESERVOIR HOSE CLUTCH PEDAL
ASSEMBLY
CLUTCH PIPE
CLUTCH HOSE
CLUTCH PIPE
CLUTCH MASTER
CYLINDER
CLUTCH
RELEASE
CYLINDER
AC406000AC
<6M/T> RESERVOIR HOSE
CLUTCH PEDAL
ASSEMBLY
CLUTCH PIPE
CLUTCH PIPE CLUTCH HOSE
CLUTCH MASTER
CYLINDER
CONCENTRIC
SLAVE
CYLINDER
AC407448AC
TSB Revision
CLUTCH
CLUTCH DIAGNOSIS
21A-3
CLUTCH DIAGNOSIS
INTRODUCTION TO CLUTCH DIAGNOSIS
M1211003400160
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 mis-
adjustment of the clutch pedal.
CLUTCH DIAGNOSIS TROUBLESHOOTING STRATEGY
M1211003500167
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer 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.
SYMPTOM CHART
M1211003600142
SYMPTOM INSPECTION REFERENCE
PROCEDURE PAGE
Clutch slips 1 P.21A-3
Clutch cannot be disengaged 2 P.21A-4
Clutch noise 3 P.21A-5
Clutch pedal feels "heavy" 4 P.21A-6
When the clutch is engaged, abnormal vibration occurs. 5 P.21A-7
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: Clutch Slips
DIAGNOSIS STEP 3. Check the release fork for sticking.
Q: Is the release fork stuck?
STEP 1. Check insufficient clutch pedal play. YES : Repair or replace the release fork (Refer to
Refer to P.21A-9. GROUP 21B, Clutch P.21B-2). Then go to
Q: Does the clutch pedal play meet the standard Step 8.
value? NO : Go to Step 5.
YES : Go to Step 2.
NO : Adjust the clutch pedal play. Then go to STEP 4. Check the concentric slave cylinder for
Step 8. deformation.
Q: Is deformation found on concentric slave cylinder?
STEP 2. Check the hydraulic system for YES : Replace the concentric slave cylinder (Refer
clogging. to P.21A-13). Then go to Step 8.
Q: Is the hydraulic system clogged? NO : Go to Step 5.
YES : Repair or replace the hydraulic system
(Refer to P.21A-13). Then go to Step 8.
NO <5M/T> : Go to Step 3.
NO <6M/T> : Go to Step 4.
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21A-4 CLUTCH
CLUTCH DIAGNOSIS
STEP 5. Check the clutch disc facing for STEP 7. Check the diaphragm spring for
excessive wear. weakness and damage.
Q: Is the clutch disc facing worn excessively? Q: Is the diaphragm spring weakened or damaged?
YES <5M/T> : Replace the clutch disc (Refer to YES <5M/T> : Replace the clutch cover assembly
GROUP 21B, Clutch P.21B-2). Then go to (Refer to GROUP 21B, Clutch P.21B-2).
Step 8. Then go to Step 8.
YES <6M/T> : Replace the clutch disc and clutch YES <6M/T> : Replace the clutch disc and clutch
cover assembly (Refer to GROUP 21C, cover assembly (Refer to GROUP 21C,
Clutch P.21C-2). Then go to Step 8. Clutch P.21C-2). Then go to Step 8.
NO : Go to Step 6. NO : Go to Step 8.
STEP 6. Check the clutch disc facing for STEP 8. Check again for the symptom.
hardening and adhesion of oil. Q: Is the symptom reproduced?
Q: Is the clutch disc facing hardened or contaminated YES : Return to Step 1.
with oil? NO : The procedure is complete.
YES <5M/T> : Replace the clutch disc (Refer to
GROUP 21B, Clutch P.21B-2). Then go to
Step 8.
YES <6M/T> : Replace the clutch disc and clutch
cover assembly (Refer to GROUP 21C,
Clutch P.21C-2). Then go to Step 8.
NO : Go to Step 7.
INSPECTION PROCEDURE 2: Clutch Cannot be Disengaged
DIAGNOSIS STEP 3. Check the release fork for sticking.
Q: Is the release fork stuck?
STEP 1. Check the excessive clutch pedal play. YES : Repair or replace the release fork (Refer to
Refer to P.21A-9. GROUP 21B, Clutch P.21B-2). Then go to
Q: Does the clutch pedal play meet the standard Step 11.
value? NO : Go to Step 5.
YES : Go to Step 2.
NO : Adjust the clutch pedal play. Then go to STEP 4. Check the concentric slave cylinder for
Step 11. deformation.
Q: Is deformation found on concentric slave cylinder?
STEP 2. Check the hydraulic system for leakage, YES : Replace the concentric slave cylinder (Refer
air mix and clogging. to P.21A-13). Then go to Step 11.
Q: Is there a leakage, air mix or clogging on the NO : Go to Step 5.
hydraulic system?
YES : Repair or replace the hydraulic system STEP 5. Check the clutch disc for distortion and
(Refer to P.21A-13). Then go to Step 11. excessive oscillation.
NO <5M/T> : Go to Step 3.
NO <6M/T> : Go to Step 4. Q: Is the clutch disc distorted or oscillating?
YES <5M/T> : Replace the clutch disc (Refer to
GROUP 21B, Clutch P.21B-2). Then go to
Step 11.
YES <6M/T> : Replace the clutch disc and clutch
cover assembly (Refer to GROUP 21C,
Clutch P.21C-2). Then go to Step 11.
NO : Go to Step 6.
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CLUTCH
CLUTCH DIAGNOSIS
21A-5
STEP 6. Check the clutch disc spline for wear STEP 9. Check the pressure plate and the
and corrosion. flywheel for damage.
Q: Is the clutch disc spline worn or corroded? Q: Is the pressure plate or the flywheel damaged?
YES <5M/T> : Replace the clutch disc (Refer to YES <5M/T> : Replace the clutch cover assembly
GROUP 21B, Clutch P.21B-2). Then go to (Refer to GROUP 21B, Clutch P.21B-2) or
Step 11. the flywheel (Refer to GROUP 11B,
YES <6M/T> : Replace the clutch disc and clutch Crankshaft and Cylinder Block P.11B-60).
cover assembly (Refer to GROUP 21C, Then go to Step 11.
Clutch P.21C-2). Then go to Step 11. YES <6M/T> : Replace the clutch disc and clutch
NO : Go to Step 7. cover assembly (Refer to GROUP 21C,
Clutch P.21C-2) or the flywheel (Refer to
STEP 7. Check the clutch disc facing for peeling. GROUP 11D, Crankshaft and Cylinder
Block P.11D-58). Then go to Step 11.
Q: Is clutch disc facing peeling? NO <5M/T> : Go to Step 10.
YES <5M/T> : Replace the clutch disc (Refer to NO <6M/T> : Go to Step 11.
GROUP 21B, Clutch P.21B-2). Then go to
Step 11.
YES <6M/T> : Replace the clutch disc and clutch STEP 10. Check the clutch release bearing for
cover assembly (Refer to GROUP 21C, wear.
Clutch P.21C-2). Then go to Step 11. Q: Is the clutch release bearing worn?
NO : Go to Step 8. YES : Replace the clutch release bearing. Then
go to Step 11.
NO : Go to Step 11.
STEP 8. Check the clutch cover assembly for
wear.
Q: Is the clutch cover assembly worn?
STEP 11. Check again for the symptom.
YES <5M/T> : Replace the clutch cover assembly Q: Is the symptom reproduced?
(Refer to GROUP 21B, Clutch P.21B-2). YES : Return to Step 1.
Then go to Step 11. NO : The procedure is complete.
YES <6M/T> : Replace the clutch disc and clutch
cover assembly (Refer to GROUP 21C,
Clutch P.21C-2). Then go to Step 11.
NO : Go to Step 9.
INSPECTION PROCEDURE 3: Clutch Noise
DIAGNOSIS STEP 2. Check the clutch release bearing for
wear.
STEP 1. Check insufficient clutch pedal play. Q: Is the clutch release bearing worn?
Refer to P.21A-9. YES : Replace the clutch release bearing (Refer to
Q: Does the clutch pedal play meet the standard GROUP 21B, Clutch P.21B-2). Then go to
value? Step 7.
YES <5M/T> : Go to Step 2. NO : Go to Step 3.
YES <6M/T> : Go to Step 4.
NO : Adjust the clutch pedal play. Then go to STEP 3. Check the clutch release bearing sliding
Step 7. surface for insufficient lubrication.
Q: Is the lubrication of the bearing sleeve sliding
surface sufficient?
YES : Go to Step 5.
NO : Repair the clutch release bearing sliding
surface. Then go to Step 7.
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21A-6 CLUTCH
CLUTCH DIAGNOSIS
STEP 4. Check the concentric slave cylinder for STEP 6. Check the clutch disc facing for
deformation. excessive wear.
Q: Is deformation found on concentric slave cylinder? Q: Is the clutch disc facing assembly worn
YES : Replace the concentric slave cylinder (Refer excessively?
to P.21A-13). Then go to Step 7. YES <5M/T> : Replace the clutch disc (Refer to
NO : Go to Step 5. GROUP 21B, Clutch P.21B-2). Then go to
Step 7.
YES <6M/T> : Replace the clutch disc and clutch
STEP 5. Check the clutch cover assembly for
cover assembly (Refer to GROUP 21C,
improper installation.
Clutch P.21C-2). Then go to Step 7.
Q: Is the clutch cover assembly installed properly? NO : Go to Step 7.
YES : Go to Step 6.
NO : Install the clutch cover assembly properly.
Then go to Step 7. STEP 7. Check again for the symptom.
Q: Is the symptom reproduced?
YES : Return to Step 1.
NO : The procedure is complete.
INSPECTION PROCEDURE 4: Clutch Pedal Feels "Heavy"
DIAGNOSIS STEP 4. Check the clutch disc spline for
insufficient lubrication.
STEP 1. Check the clutch pedal clevis pin for Q: Is the lubrication of the clutch disc spline
insufficient lubrication. sufficient?
YES <5M/T> : Go to Step 5.
Q: Is the lubrication of the clutch pedal clevis pin
sufficient? YES <6M/T> : Go to Step 6.
YES <5M/T> : Go to Step 2. NO : Repair the clutch disc spline. Then go to
YES <6M/T> : Go to Step 3. Step 6.
NO : Repair the clutch pedal. Then go to Step 6.
STEP 5. Check the insufficient lubrication of
STEP 2. Check the release fork for sticking. clutch release bearing sliding surface.
Q: Is the release fork stuck? Q: Is the lubrication of the bearing sleeve sliding
YES : Repair or replace the release fork (Refer to surface sufficient?
GROUP 21B, Clutch P.21B-2). Then go to YES : Go to Step 6.
Step 6. NO : Repair the clutch release bearing sliding
NO : Go to Step 5. surface. Then go to Step 6.
STEP 3. Check the concentric slave cylinder for STEP 6. Check again for the symptom.
deformation. Q: Is the symptom reproduced?
YES : Return to Step 1.
Q: Is deformation found on concentric slave cylinder?
YES : Replace the concentric slave cylinder (Refer NO : The procedure is complete.
to P.21A-13). Then go to Step 6.
NO : Go to Step 5.
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CLUTCH
CLUTCH DIAGNOSIS
21A-7
INSPECTION PROCEDURE 5: When the Clutch is Engaged, Abnormal Vibration Occurs.
DIAGNOSIS STEP 4. Check the diaphragm spring for uneven
height.
.
STEP 1. Check the engine and transaxle Q: Is the diaphragm spring even height?
mounting for loosening and damage. YES : Go to Step 5.
NO <5M/T> : Replace the clutch cover assembly
Q: Is the engine and transaxle mounting loosened or (Refer to GROUP 21B, Clutch P.21B-2).
damaged? Then go to Step 8.
YES : Tighten or replace the engine and transaxle NO <6M/T> : Replace the clutch disc and clutch
mounting. Then go to Step 8. cover assembly (Refer to GROUP 21C,
NO <5M/T> : Go to Step 2.
Clutch P.21C-2). Then go to Step 8.
NO <6M/T> : Go to Step 3.
STEP 5. Check the pressure plate and flywheel
STEP 2. Check the release fork for sticking.
for damage.
Q: Is the release fork stuck?
Q: Is the pressure plate or flywheel damaged?
YES : Repair or replace the release fork (Refer to
YES <5M/T> : Replace the clutch cover assembly
GROUP 21B, Clutch P.21B-2). Then go to
(Refer to GROUP 21B, Clutch P.21B-2) or
Step 8.
the flywheel (Refer to GROUP 11B,
NO : Go to Step 4.
Crankshaft and Cylinder Block P.11B-60).
Then go to Step 8.
STEP 3. Check the concentric slave cylinder for YES <6M/T> : Replace the clutch disc and clutch
deformation. cover assembly (Refer to GROUP 21C,
Q: Is deformation found on concentric slave cylinder? Clutch P.21C-2) or the flywheel (Refer to
YES : Replace the concentric slave cylinder (Refer GROUP 11D, Crankshaft and Cylinder
to P.21A-13). Then go to Step 8. Block P.11D-58). Then go to Step 8.
NO : Go to Step 4. NO : Go to Step 6.
STEP 6. Check the clutch disc facing for wear
and damage.
Q: Is the clutch disc facing worn or damaged?
YES <5M/T> : Replace the clutch disc (Refer to
GROUP 21B, Clutch P.21B-2). Then go to
Step 8.
YES <6M/T> : Replace the clutch disc and clutch
cover assembly (Refer to GROUP 21C,
Clutch P.21C-2). Then go to Step 8.
NO : Go to Step 7.
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21A-8 CLUTCH
CLUTCH DIAGNOSIS
STEP 7. Check for grease or oil on the clutch disc STEP 8. Check again for the symptom.
facing. Q: Is the symptom reproduced?
Q: Is there grease or oil on the clutch disc facing? YES : Return to Step 1.
YES <5M/T> : If the clutch disc facing is NO : The procedure is complete.
contaminated with grease or oil, check that
grease is applied to the clutch disc spline.
Then check the clutch housing input shaft oil
seal (Refer to GROUP 22B, Clutch Housing
P.22B-42) and the crank shaft rear oil seal
(Refer to GROUP 11A, Crankshaft Oil Seal
P.11A-38) for leakage, and replace the oil
seal(s). Replace the clutch disc (Refer to
GROUP 21B, Clutch P.21B-2). Then go to
Step 8.
YES <6M/T> : If the clutch disc facing is
contaminated with grease or oil, check that
grease is applied to the clutch disc spline.
Then check the clutch housing input shaft oil
seal (Refer to GROUP 22C, Clutch Housing
P.22C-47) and the crank shaft rear oil seal
(Refer to GROUP 11C, Crankshaft Rear Oil
Seal P.11C-53) for leakage, and replace the
oil seal(s). Replace the clutch disc and
clutch cover assembly (Refer to GROUP
21C, Clutch P.21C-2). Then go to Step 8.
NO : Go to Step 8.
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CLUTCH
ON-VEHICLE SERVICE
21A-9
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND ADJUSTMENT
M1211000900359
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):
<5M/T> 169.4 mm (6.67 inches) [From the surface of
dash panel to the face of pedal pad]
<6M/T> 178.2 mm (7.02 inches) [From the surface of
A B dash panel to the face of pedal pad]
3. Measure the clutch pedal clevis pin play. If the play is
outside the standard value, go to Step 5.
AC001133AB
Standard value (B): 1 - 3 mm (0.04 - 0.12 inch)
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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