CLUTCH SYSTEM

CLUTCH
CLUTCH UNIT (AIR SERVO TYPE)
 CLUTCH

CONTENTS
SERVICE DATA ......................................... CL- 1- 1 DISASSEMBLY ......................................... CL- 3- 3
SPECIFICATIONS ...................................... CL- 1- 1 REMOVAL .................................................. CL- 3- 3
SERVICE DATA ......................................... CL- 1- 2 DISASSEMBLY .......................................... CL- 3- 6
TIGHTENING TORQUE ............................. CL- 1- 3 INSPECTION .............................................. CL- 3-12
TOOLS ......................................................... CL- 2- 1 REASSEMBLY .......................................... CL- 3-16
REASSEMBLY ........................................... CL- 3-16
= UNIT NAME CLB10, CL650 = INSTALLATION .......................................... CL- 3-21
ADJUSTMENT ........................................... CL- 3-24
CONSTRUCTION ..................................... CL- 3- 1

SUPPLEMENTAL OUTLINE
+ Addition of a unit due to introduction of a new vehicle model
 SERVICE DATA CLUTCH PROPER

SERVICE DATA
SPECIFICATIONS
UNIT NAME CLB10, CL650
Unit name CLB10 CL650
Type Diaphragm type dual disc, dry Diaphragm type single disc, dry
Facing dimensions 400 x 250 x 10.4 430 x 250 x 11.9
Clutch disc (OD x ID x thickness when compressed) mm (in) (15.748 x 9.843 x 0.409) (15.929 x 9.843 x 0.469)
Material Semi-mold
Clutch operating system Hydraulic system (air booster)

UNIT NAME
CL B 10

Clutch Disc size mm (in) Clutch cover set load N {kgf, lbf}

B 400 (15.75) B 10 20,055 {2,045, 4,509}

6 430 (16.93) 6 50 22,556 {2,300, 5,071}

CL-1-1
 SERVICE DATA CLUTCH PROPER

SERVICE DATA
UNIT NAME CLB10, CL650
Unit: mm (in)
Item Maintenance standard Service limit Remarks
CLB10 Less than 1.0 (0.039) 1.4 (0.055)
Runout
CL650 — 1.4 (0.055)
Clutch disc
Facing thickness (one side) — 0.2 (0.008) Above rivet head
Play in radial direction of spring Less than 0.285 (0.0112) 0.5 (0.020)
CLB10 Less than 0.1 (0.004) 0.25 (0.0098)
Flatness of contact surface
CL650 Less than 0.1 (0.004) 0.2 (0.008)
0.2 - 0.3 (0.008 - 0.012) Less than 0 Below zero indicates that
Taper of contact surface at outer
(Outer end is higher than More than 0.5 inner end is higher than
Clutch pres- section
inner end.) (0.020) outer end.
sure plate
59.03 - 59.13
CLB10 57.8 (2.276)
Thickness of contact (2.3240 - 2.3279)
surface 64.67 - 64.77
CL650 62.72 (2.469)
(2.5461 - 2.5500)
Flatness of contact
Less than 0.1 (0.004) 0.15 (0.0059)
surface
Pressure plate
side Taper of contact 0.2 - 0.3 (0.008 - 0.012) Less than 0 Below zero indicates that
Clutch inter- surface at outer (Inner end is higher than More than outer end is higher than in-
mediate section outer end.) 0.5 (0.020) ner end.
plate
(CLB10 only) Flywheel side Flatness of contact
Less than 0.05 (0.0020) 0.15 (0.0059)
surface
Wear limit on one side:
Thickness of contact surface 37.5 - 37.7 (1.476 - 1.484) 33.6 (1.323)
2 mm (0.08 in)
118.4 - 118.6
CLB10 —
Diaphragm spring height (4.661 - 4.669)
Clutch cover CL650 82.3 - 84.3 (3.240 - 3.319) —
assembly
Diaphragm spring height CLB10 Less than 1.0 (0.039) —
difference CL650 Less than 1.0 (0.039) —
CLB10 Less than 0.1 (0.004) 0.15 (0.0059)
Flatness of contact surface
CL650 Less than 0.1 (0.004) 0.2 (0.008)

Flywheel Thickness (A)

CLB10 —
Decrease in thickness of 50.4 - 50.6 (1.984 - 1.992)
contact surface Height (H)
CL650 49.1 (1.933)
47.9 - 48.1 (1.886 - 1.894)
Release lever bushing ID 12.7 (0.500) —
Lever pin and support pin OD 12.7 (0.500) 12.5 (0.492)

Clutch re- Support ID 12.7 (0.500) 12.9 (0.508)

lease 34.990 - 35.015
mechanism Release shaft OD —
(1.3776 - 1.3785)
Release bearing wear — 0.5 (0.020)
Clutch outer lever play 4.5 - 5.5 (0.177 - 0.217)

CL-1-2
 SERVICE DATA CLUTCH PROPER

TIGHTENING TORQUE
Unit: N·m {kgfzm, ftzlbf}
Item Tightening torque
Clutch cover mounting bolt 41 - 52 {4.2 - 5.3, 30 - 38}
Clutch cover assembly set bolt CLB10 15 - 27 {1.5 - 2.8, 11 - 20}
Strap plate mounting reamer bolt CLB10 59 - 78 {6.0 - 8.0, 43 - 58}
Clutch housing mounting nut (Flywheel housing side) 37 - 49 {3.8 - 5.0, 27 - 36}
Clutch housing drain plug (MRT23 T/M only) 118 - 137 {12.0 - 14.0, 87 - 101}

CL-1-3
 TOOLS CLUTCH PROPER

TOOLS
Tool name and number Description Shape

Used to center clutch disc and to

Setting shaft 99797 Z0071 inspect and adjust the height of re-
lease levers (diaphragm spring).

WCL152A

Clutch cover Used to remove and install the pull

99783 Z0001
hanging tool type clutch cover assembly

WCL153A

Used to pull back the diaphragm

99793 Z0000 1.0 mm (0.039 in) spring when removing the pull type
99793 Z0001 2.0 mm (0.079 in) clutch cover assembly from the fly-
Clutch space 99793 Z0002 3.0 mm (0.118 in) wheel
block 99793 Z0003 4.0 mm (0.157 in) t = 1.0 - 6.0 mm (0.039 - 0.236 in)
99793 Z0004 5.0 mm (0.197 in) [in increments of 1.0 mm (0.039 in)]
99793 Z0005 6.0 mm (0.236 in) While new = 6.0 mm (0.0236 in)
(Standard)
CTL1112

Yoke bearing Used to install the release yoke

99796 Z0002
replacer bearing

WCL207A

CL-2-1
 CONSTRUCTION CLB10, CL650

= UNIT NAME CLB10, CL650 =

CONSTRUCTION
CLUTCH COVER AND CLUTCH HOUSING ASSEMBLY
Transmission model CLB10

WCL154A

CL-3-1
 CONSTRUCTION CLB10, CL650

Transmission model CL650

WCL201A

CL-3-2
 DISASSEMBLY CLB10, CL650

DISASSEMBLY
REMOVAL
Key point of removal
<Removal of transmission equipped with pull type
clutch>
1. Before removing the clutch assembly, turn the key switch to the
‘‘OFF’’ position and chock the wheels.
2. Be sure to remove the clutch booster and bracket as a unit from
the transmission, and fasten to the frame with twine.

3. Before disconnecting harnesses from the transmission, attach

an identification tag to the harness couplers on the sides of the
transmission and chassis.

WCL155A

4. Remove the clutch booster air hose together with the joint
connector bracket from the rear part of the clutch booster.
5. Remove the rod side of the clutch booster together with the
connecting part of the outer lever, removing the main body of
the clutch booster together with the mounting bracket from the
transmission case.
NOTE
+ Do not loosen the hose on the oil side of the clutch
booster. If the hose is removed or loosened, be sure to
bleed the air.
+ Hang the removed clutch booster using a return spring to WCL156A
a place where it is not in the way.

6. Remove the release sleeve grease hose from the stay and
push the grommet into the clutch housing.
7. Remove the speedometer cable.
8. Attach an identification tag to the oil cooler hose and discon-
nect it.
9. If PTO is equipped, remove the PTO drive shaft.
10. If the transmission is to be disassembled, drain the transmis-
sion gear oil at this time.
11. Set a transmission jack or crane to the transmission.
12. Remove the flywheel housing mounting bolts and nuts.
WCL157A

CL-3-3
 DISASSEMBLY CLB10, CL650

13. While pulling the transmission rearward to separate the clutch

release yoke from the release sleeve, pull up the clutch outer
lever to the horizontal position.
14. Pull the transmission rearward until the main drive shaft fully
comes out of the clutch cover.
CAUTION
+ Make sure the grease hose does not catch the outer lever
while pulling rearward.
15. Pull the transmission out from under the vehicle.
WCL158A

<Removal of clutch cover>

1. Lower the clutch cover hanging tool (99783 Z0001) from
between the rear cab mount and rear body.
NOTE
+ Before removing the clutch cover, be sure to remove the
special tool spring.

WCL153A

2. Attach a mark (top mark) on the upper part of the clutch cover
to facilitate attachment of a hanging tool.

WCL159A

3. Insert the hanging tool between the clutch cover and dia-
phragm spring.
4. Install the clutch setting shaft (99797 90071).

WCL160A

5. Measure the clearance between the cover and reamer bolts

which are located on the outer periphery of the clutch cover.
6. Set space blocks (99793 Z0000 - 99793 Z0005) which corre-
spond to the clearance dimension in 4 places.
NOTE
+ Loosen the clutch cover mounting bolts and nuts to
secure the space blocks between the clutch cover and
reamer bolt.

WCL161A

CL-3-4
 DISASSEMBLY CLB10, CL650

7. Remove the clutch cover mounting bolts and nuts to remove

the clutch cover.
WARNING
+ Do not tilt the clutch cover more than 45 degrees while it
is being hanged. Doing so could cause the hanging tool
to come off.

CAUTION
+ Be careful not to bend the stud bolts while removing the
WCL162A
clutch cover.
8. Slowly lower the removed clutch cover to the lower part of the
vehicle and pull it out from under the vehicle by using a cart,
etc.

CL-3-5
 DISASSEMBLY CLB10, CL650

DISASSEMBLY
CLUTCH COVER
Transmission model CLB10

WCL163A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

>j
1 Adjuster assembly j9 Flywheel ring >.j
16 Reamer bolt
j
2 Cover assembly set bolt j
10 Knock pin >j
17 Washer
j
3 Pressure plate & cover assembly .j
11 Retaining ring j
18 Clip
j
4 Clutch disc j
12 Release plate j
19 Cover
j
5 Flywheel ring assembly >.j
13 Release sleeve assembly >j
20 Wire ring
>j
6 Washer j
14 Corn spring >j
21 Diaphragm spring
>j
7 Strap plate (4 sheets) j
15 Support plate >j
22 Collar
j
8 Intermediate plate >j
23 Pressure plate
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

CL-3-6
 DISASSEMBLY CLB10, CL650

Key point of disassembly

j
11 Retaining ring
j
13 Release sleeve assembly
1. Push the release plate against the side of the diaphragm spring
to provide clearance to the retaining ring.

WCL164A

2. Remove the retaining ring using a retaining ring holder and

remove the release plate.
3. Extract the release sleeve assembly from the cover assembly.
4. Remove the cone spring and support plate from the release
sleeve.

WCL165A

j
16 Reamer bolt
1. Place the pressure plate and cover assembly on a hydraulic
press with the side of the cover facing up.

CCL1110L

2. Push the cover down with a hydraulic press and remove the
reamer bolts and space blocks.
3. Remove the clips and mounting bolts.

WCL166A

4. Slowly loosen the hydraulic press.

5. Disassemble the cover assembly into the pressure plate,
diaphragm spring, wire ring, collar and cover.

WCL167A

CL-3-7
 DISASSEMBLY CLB10, CL650

Transmission model CL650

JCL033A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Clutch disc j
3 Clutch cover assembly j
5 Roll pin
j
2 Pressure plate j
4 Release sleeve assembly j
6 Clutch housing
NOTE
+ For details, refer to the CLB10 model.

CL-3-8
 DISASSEMBLY CLB10, CL650

CLUTCH HOUSING
Transmission model MRT23

WCL202A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Grease nipple j
7 Release yoke j
13 Rubber seat
j
2 Hose support >j8 Bearing assembly j
14 Under cover
j
3 Grease hose j9 Oil seal j
15 Rubber seat
j
4 Release yoke set bolt j
10 Needle bearing j
16 Grease nipple
.j
5 Feather key j
11 Air cleaner j
17 Clutch housing
>j
6 Release shaft j
12 Top cover
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

CL-3-9
 DISASSEMBLY CLB10, CL650

Transmission model MTS73

WCL203A

Disassembly sequence (Reassembly sequence is in the reverse order of disassembly.)

j
1 Grease nipple j
7 Release yoke j
13 Rubber seat
j
2 Hose support >j8 Bearing assembly j
14 Under cover
j
3 Grease hose j9 Oil seal j
15 Rubber seat
j
4 Release yoke set bolt j
10 Needle bearing j
16 Grease nipple
.j
5 Feather key j
11 Air cleaner j
17 Clutch housing
>j
6 Release shaft j
12 Top cover
Marks ‘‘.’’ and ‘‘>’’ indicate that the key points of operation are explained in the text.

CL-3-10
 DISASSEMBLY CLB10, CL650

Key point of disassembly

j5 MRT23, MTS73 Feather key
Remove the wires, set bolts and feather key.
NOTE
+ Always remove the release yoke from the feather key first,
and then detach the key from the release shaft assembly.

CCL1-019

CL-3-11
 INSPECTION CLB10, CL650

INSPECTION
+ Clean all disassembled parts in cleaning solvent. Check for
scratches, cracks or damage and replace faulty parts.
+ If measurement indicates that the repair limit or wear limit has
exceeded, repair or replace faulty parts.

CLUTCH DISC
Runout
Unit: mm (in)
Unit name Maintenance standard Service limit
CLB10 Less than 1.0 (0.039) 1.4 (0.055)
CL650 — 1.4 (0.055)

CCL1-021

Tension spring play

Check the torsion spring for lateral play. If any play is present,
replace the clutch disc assembly.

CCL1-022

Facing thickness (one side)

Unit: mm (in)
Maintenance standard Service limit (H) Remarks
0.2 (0.008) Wear limit on one side:
—
(above rivet head) 1.3 mm (0.051 in)

CCL1023A

Play in radial direction of spline

Unit: mm (in)
Maintenance standard Service limit
Less than 0.285 (0.0112) 0.5 (0.020)

CCL1024D

CL-3-12
 INSPECTION CLB10, CL650

CLUTCH PRESSURE PLATE

Flatness of contact surface
Unit: mm (in)
Unit name Maintenance standard Service limit
CLB10 Less than 0.1 (0.004) 0.25 (0.0098)
CL650 Less than 0.1 (0.004) 0.2 (0.008)

CCL1-025

Taper of contact surface at outer section

Unit: mm (in)
Maintenance standard Service limit Remarks
0.2 - 0.3
Below zero indicates that
(0.008 - 0.012) Less than 0
inner end is higher than
(Outer end is higher than More than 0.5 (0.020)
outer end.
inner end.)

CCL1-026

Thickness of contact surface

Unit: mm (in)
Unit name Maintenance standard Service limit
59.03 - 59.13
CLB10 57.8 (2.276)
(2.3240 - 2.3279)
64.67 - 64.77
CL650 62.72 (2.469)
(2.5461 - 2.5500)

CCL1028A

CLUTCH INTERMEDIATE PLATE

Flatness of contact surface
(Pressure plate side)
Unit: mm (in)
Maintenance standard Service limit
Less than 0.1 (0.004) 0.15 (0.0059)

CCL1-066

Taper of contact surface at outer section

(Pressure plate side)
Unit: mm (in)
Maintenance standard Service limit Remarks
0.2 - 0.3
Below zero indicates that
(0.008 - 0.012) Less than 0
inner end is higher than
(Outer end is higher than More than 0.5 (0.020)
outer end.
inner end.)

CCL1-067

CL-3-13
 INSPECTION CLB10, CL650

Flatness of contact surface

(Flywheel side)
Unit: mm (in)
Maintenance standard Service limit
Less than 0.05 (0.0020) 0.15 (0.0059)

CCL1-066

Thickness of contact surface

Unit: mm (in)
Maintenance standard Service limit Remarks
37.5 - 37.7 Wear limit on one side:
33.6 (1.323)
(1.476 - 1.484) 2 mm (0.08 in)

CCL1-068

CLUTCH COVER ASSEMBLY

Diaphragm spring height
Unit: mm (in)
Unit name Maintenance standard Service limit
CLB10 118.4 - 118.6 (4.661 - 4.669) —
CL650 82.3 - 84.3 (3.240 - 3.319) —

Diaphragm spring height difference WCL204A

Unit: mm (in)
Maintenance standard Service limit
Less than 1.0 (0.039) —

WCL205A

FLYWHEEL
Flatness of contact surface
Unit: mm (in)
Unit name Maintenance standard Service limit
CLB10 Less than 0.1 (0.004) 0.15 (0.0059)
CL650 Less than 0.1 (0.004) 0.2 (0.008)

CCL1030C

CL-3-14
 INSPECTION CLB10, CL650

Decrease in thickness of contact surface

Unit: mm (in)
Unit name Item Maintenance standard Service limit
CLB10 Thickness (A) 50.4 - 50.6 (1.984 - 1.992) —
CL650 Height (H) 47.9 - 48.1 (1.886 - 1.894) 49.1 (1.933)

JCL042A

JCL041A

Release shaft outside diameter

Unit: mm (in)
Maintenance standard Service limit
34.990 - 35.015 (1.3776 - 1.3785) —

CCL1-038

CL-3-15
 REASSEMBLY CLB10, CL650

REASSEMBLY
REASSEMBLY
CLUTCH COVER
Key point of reassembly
j23 Pressure plate
Set the pressure plate on a hydraulic press with the side of the
cover facing up.

CCL1110T

j22 Collar
Install the collars to the pressure plate.

WCL169A

j
21 Diaphragm spring
1. Apply molybdenum based grease to both faces of the dia-
phragm spring.

WCL170A

2. Put the diaphragm spring on the pressure plate with the

protruded side facing the side of the plate.

WCL171A

3. Install the clips and bolts to the collar.

WCL172A

CL-3-16
 REASSEMBLY CLB10, CL650

j
20 Wire ring
1. Insert the wire ring into the inside of the cover.

WCL173A

2. Put the cover on the installed diaphragm spring.

WCL174A

j
17 Washer
j
16 Reamer bolt
1. Temporarily install the reamer bolts with the washers placed
between the cover and plate.

WCL175A

2. Attach a wooden block to the upper surface of the cover and

compress the diaphragm spring with a hydraulic press until the
cover comes into contact with the pressure plate.

CCL1111

3. Tighten the reamer bolts and clip set bolts.

: Reamer bolt
59 - 78 N·m {6.0 - 8.0 kgfzm, 43 - 58 ftzlbf}
Clip set bolt
15 - 27 N·m {1.5 - 2.8 kgfzm, 11 - 20 ftzlbf}

CL-3-17
 REASSEMBLY CLB10, CL650

4. Insert a space block between each strap set bolt head and
cover.

WCL176A

5. Slowly loosen the hydraulic press, being careful not to dislocate

the space blocks.

j
13 Release sleeve assembly
1. Set the support plate and cone spring to the release sleeve
assembly. Insert the release sleeve assembly into the dia-
phragm spring (from the side without the pressure plate) and
secure the release sleeve assembly with the release plate and
retaining ring.

WCL165A

2. Set the intermediate plate to the flywheel ring.

WCL177A

j7 Strap plate (4 sheets)

j6 Washer
Connect the flywheel ring and intermediate plate using the strap
plate.
: 59 - 78 N·m {6.0 - 8.0 kgfzm, 43 - 58 ftzlbf}
NOTE
+ Install the four (4) strap plates and two (2) washers as a
set.
+ Before tightening, apply LOCTITE No. 272 to the strap set
bolts. WCL178A

CL-3-18
 REASSEMBLY CLB10, CL650

+ Adjustment of strap plates

+ No. of strap plates required
Location of strap plate No. of strap plates
Between flywheel and intermediate plate
4 per location (Total: 16)
Between clutch cover and pressure plate

All of the strap plates are exactly the same in design.

WCL179A

+ Adjusting the installed height of strap plates

WCL180A

1. If a worn intermediate plate is used or if it has been rema-

chined, place plain adjustment washers between the strap
plates at the intermediate plate location to compensate for the
total amount of wear.
Total wear amount of intermediate plate No. of adjustment plain washers re-
and flywheel [mm (in)] quired
Less than 0.5 (0.020) None
0.5 - 1.5 (0.020 - 0.059) 1
1.5 - 2.5 (0.059 - 0.098) 2
2.5 - 3.5 (0.098 - 0.138) 3
3.5 - 4.0 (0.138 - 0.157) 4

CL-3-19
 REASSEMBLY CLB10, CL650

2. Install the spring washer, plain washer and strap plate to the
pressure plate with the reamer bolt in place.
: 59 - 78 N·m {6.0 - 8.0 kgfzm, 43 - 58 ftzlbf}

j1 Adjuster assembly
1. Make sure the adjuster assembly sleeve does not protrude
from the holder. If it does, secure the holder and tap the pin in
the direction of the arrow to flush the sleeve with the holder
surface.

WCL181A

WCL182A

2. Connect the intermediate plate and pressure plate with the

adjuster assembly.
: 15 - 27 N·m {1.5 - 2.8 kgfzm, 11 - 20 ftzlbf}

WCL183A

CLUTCH HOUSING
Key point of reassembly
j8 MRT23, MTS73 Bearing assembly
When press-fitting the yoke bearing into the release yoke, use the
special tool bearing replacer (99796 Z0002) provided for this
purpose. If it is press-fitted without using the special tool, sufficient
clearance in the bearing will not be provided; this may result in
rough bearing rotation.

WCL208A

CL-3-20
 REASSEMBLY CLB10, CL650

j6 MRT23, MTS73 Release shaft

Insert the release shaft assembly into the clutch housing, fit the
release yoke onto the shaft, and then install the feather key, set
bolt and wire on the release yoke.
NOTE
+ Be sure to install the release yoke in the proper direction.

CCL1-019

INSTALLATION
Key point of installation
<Clutch assembly>
1. After assembling the clutch cover, install the clutch disc and
clutch cover to the flywheel housing using a setting tool.
NOTE
+ Clean the flywheel and intermediate plate prior to reassem-
bly.
+ Ensure that the lower boss of the clutch disc (on the
flywheel side) faces the intermediate plate.
+ Be sure to align the dowel pins when installing the clutch
cover assembly.

2. Hang up the clutch cover using the clutch cover hanging tool
(99783 Z0001) from the top mark position which is marked
before removing the clutch cover.
NOTE
+ Before hanging up the clutch cover, be sure to set the
special tool spring.
+ When installing a new cover assembly, hang up from the
same position as the removed clutch cover.

WCL159A

3. Set the clutch setting shaft (99797 Z0071) and clutch disc to the
clutch cover.
NOTE
+ Install the clutch disc with the side of the protruded spline
boss facing the side of the flywheel.
4. Install the clutch cover using the flywheel stud bolt as a guide
bolt.

CCL1110F

CL-3-21
 REASSEMBLY CLB10, CL650

NOTE
+ When installing the clutch cover, be careful not to bend the
flywheel stud bolts.
+ Connect the pipe to the clutch setting tool and incline it to
the same angle as the engine, then install the clutch cover.
5. Install the clutch cover so that the tip of the clutch setting shaft
enters the pilot bearing.
6. Tighten the clutch cover mounting bolts and nuts.
: 41 - 52 N·m {4.2 - 5.3 kgfzm, 30 - 38 ftzlbf}
7. Remove the 4 space blocks from the pressure plate. WCL184A
8. Extract the clutch setting shaft.

<Transmission assembly>
1. To facilitate installation of the transmission, engage gears so
that the main drive shaft can rotate.
2. Using a transmission jack or crane, set the main drive shaft so
that its tip is located in the center of the clutch cover.

3. Set the clutch outer lever to the horizontal position.

WCL185A

4. Move the transmission forward while turning the main drive

shaft slowly.
NOTE
+ While performing operations, make the grease hose some-
what tight so that the part on the release sleeve where the
grease hose is installed is always located above the clutch
cover.

CCL1111M

CL-3-22
 REASSEMBLY CLB10, CL650

5. Pass the grease hose of the release sleeve installed to the

clutch cover through the grease hose installation hole in the
transmission front case. Securing of the grommet should be
done after installing the transmission.
6. Move the transmission forward until the clutch yoke comes into
contact with the clutch cover.

WCL186A

7. At a position of 4 to 5 cm (0.16 to 0.20 in) before the clutch

housing comes into contact with the flywheel housing, push
down to turn the release lever and move the transmission
further forward to set the yoke to the sleeve. Move the
transmission further forward until it comes into contact with the
flywheel housing.
8. Tighten the transmission mounting nuts.
: 37 - 49 N·m {3.8 - 5.0 kgfzm, 27 - 36 ftzlbf}

WCL187A

9. Pull out the grease hose and secure it with the grommet.
10. Remove the transmission jack or crane from the transmission.
11. If equipped with a PTO, install the PTO drive shaft.
12. Install the oil cooler hose.
13. Install the speedometer cable.

WCL188A

14. Install the clutch booster.

15. Connect the air hose to the joint connector located at the rear
part of the clutch booster.
16. Install each linkage on the shift and select sides of the
transmission.

WCL156A

17. Connect wiring of each switch and sensor.

18. Install the propeller shaft.
19. Assemble the parts which are disassembled.
20. Pour in transmission gear oil to the level plug position.
21. Start the engine and make sure there are no air and oil leaks.
22. Operate the clutch and transmission to make sure there is no
abnormality.

CL-3-23
 ADJUSTMENT CLB10, CL650

ADJUSTMENT
CLUTCH PEDAL PLAY
Depress the clutch pedal by hand until resistance is felt. While
holding the clutch pedal in this position, measure the stroke length
of pedal play. If it is outside the specified range, adjust as follows:
Unit: mm (in)
Maintenance standard Service limit
35 - 55 (1.38 - 2.17) —

DC-065E

PEDAL PLAY ADJUSTMENT

Clutch master cylinder
1. Loosen the lock nut on the push rod.
2. Turn the push rod until it touches the piston and there is no play.
Under this condition, return the push rod one turn and make sure
the free play is approximately 1 mm (0.04 in).
3. Tighten the lock nut while holding the push rod stationary with
a wrench.

DF-101E

Clutch outer lever

1. Remove the return spring.
2. Loosen the push rod lock nut.
3. Adjust the play of the outer lever by turning the push rod.
Unit: mm (in)
Item Maintenance standard
Clutch outer lever play 4.5 - 5.5 (0.177 - 0.217)

4. Tighten the lock nut.

5. Reinstall the return spring. WCL008A

CHECKING FOR WEAR ON THE CLUTCH DISC

To properly check for wear on the clutch disc in the vehicle,
proceed as follows:
[Vehicles with clutch wear indicators]
1. Adjust free play of the outer lever and check the position of the
clevis pin on the wear indicator. If the clevis pin reaches the
MIN. position, replace the clutch disc.
2. After installing a new clutch disc, be sure the clevis pin points
to the ‘‘SET’’ position. If it does not, measure dimension ‘‘L’’ (as
outlined above) to make sure it is within the standard value. CCL1-094
If ‘‘L’’ is not outside the standard value, check and adjust the
clutch itself; if it is, proceed to the instructions under ‘‘Clutch
disc wear indicator installation and adjustment procedure’’
below.

CL-3-24
 ADJUSTMENT CLB10, CL650

CLUTCH DISC WEAR INDICATOR INSTALLATION AND

ADJUSTMENT PROCEDURE
[After installing new clutch disc]
NOTE
+ Be sure the clutch is properly adjusted.
1. Tighten the indicator stay to the clutch housing-to-flywheel
housing stud.
2. Adjust the outer lever play to the specified value.
3. Align the ‘‘SET’’ position of the indicator with the end of the
WCL011A
clevis pin, and secure the indicator. The clearance between the
clevis pin and the indicator must be 3 to 5 mm (0.12 to 0.20 in).
NOTE
+ To properly adjust the wear indicator, be sure dimension
‘‘L’’ is within the standard value.
4. Fully depress the clutch pedal several times, then check to be
sure the end of the clevis pin is at the ‘‘SET’’ position.

CCL1-094

[After installing old clutch disc]

NOTE
+ Do not loosen or remove the bolts which hold the clutch
wear indicator and stay.
+ Be sure the clutch indicator is properly adjusted.
1. Tighten the indicator stay to the clutch housing-to-flywheel
housing stud.
2. Adjust the outer lever play to the specified value.
3. The clearance between the clevis pin and the indicator must be
3 to 5 mm (0.12 to 0.20 in). WCL011A
4. Check to make sure the clevis pin points to the mark previously
chalked on the wear indicator.
5. Depress the clutch pedal several times before re-checking the
position of the clevis pin.

CCL1094A

CL-3-25