GI

CLUTCH
MA

MODIFICATION NOTICE:
SECTION CL EM

LC

EC
I The TB48DE engine model has been added for the Middle East.
I Service Data and Specifications (SDS) have been changed.
FE

CONTENTS
CLUTCH SYSTEM...........................................................2 Clutch Cover ................................................................5 MT
HYDRAULIC CLUTCH CONTROL .................................3 SERVICE DATA AND SPECIFICATIONS (SDS) ............6
Clutch Operating Cylinder ...........................................3 General Specifications.................................................6
Clutch Master Cylinder ................................................4 Inspection and Adjustment ..........................................6
AT
CLUTCH DISC AND CLUTCH COVER ..........................5
TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX

CL-1
CLUTCH SYSTEM

SCL906

CL-2
HYDRAULIC CLUTCH CONTROL

Clutch Operating Cylinder GI

MA

EM

LC

EC

FE

MT
SCL907

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX

CL-3
HYDRAULIC CLUTCH CONTROL

Clutch Master Cylinder

SCL908

CL-4
CLUTCH DISC AND CLUTCH COVER

Clutch Cover GI
INSTALLATION
Model 300 MA
I Apply recommended grease to contact surface of splines.
I Too much lubricant may damage clutch disc facing. EM
I Insert Tool into clutch disc hub when installing clutch cover and
disc.
I Be careful not to allow grease to contaminate clutch facing. LC
I Tighten bolts in numerical order, in two steps.
First step:
: 10 - 20 N⋅m (1.0 - 2.0 kg-m, 7 - 14 ft-lb) EC
Final step:
: 29 - 39 N⋅m (2.9 - 4.0 kg-m, 21 - 28 ft-lb)
FE

MT
SCL909
AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX

CL-5
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
CLUTCH CONTROL SYSTEM CLUTCH BOOSTER
Unit: mm (in)
Type of clutch control Hydraulic
Type M45

Diaphragm diameter 114.3 (4.50)

CLUTCH MASTER CYLINDER (with clutch
damper) Check valve type Built-in hose type
Unit: mm (in)

Inner diameter 17.46 (11/16)

CLUTCH OPERATING CYLINDER

Unit: mm (in)

Inner diameter 20.64 (13/16)

CLUTCH DISC
ZD30DDTi TB45E TD42 TB48DE TD42 TB45S

Applied model 275 300 275

H/T and Wagon Wagon Pickup

Facing size 275 x 180 x 3.5 275 x 180 x 3.5 275 x 180 x 3.5 300 x 190 x 3.5 275 x 180 x 3.5 275 x 180 x 3.5
(Outer dia. x inner dia. (10.83 x 7.09 x (10.83 x 7.09 x (10.83 x 7.09 x (11.81 x 7.48 x (10.83 x 7.09 x (10.83 x 7.09 x
x thickness) mm (in) 0.14) 0.14) 0.14) 0.14) 0.14) 0.14)

Thickness of disc 7.8 - 8.4 7.8 - 8.4 7.8 - 8.2 7.7 - 8.3 7.8 - 8.2 7.8 - 8.4
assembly with load (0.31 - 0.33) (0.31 - 0.33) (0.31 - 0.32) (0.30 - 0.33) (0.31 - 0.32) (0.31 - 0.33)
mm (in)/N (kg, lb) /7,846 (800, 1,764) /7,846 (800, 1,764) /6,865 (700, 1,544) /8,336 (850, 1,874) /5,394 (550, 1,213) /7,846 (800, 1,764)

CLUTCH COVER
ZD30DDTi TB45E TD42 TB48DE TD42 TB45S
Applied
275 300 275
model
H/T Wagon Wagon Pickup

6,473 - 7,257 7,355 - 8,336 7,355 - 8,336 5,492 - 6,276 7,649 - 9,022 5,492 - 6,276 6,473 - 7,257
Full load
(660 - 740, 1,455 (750 - 850, 1,654 (750 - 850, 1,654 (560 - 640, 1,235 (780 - 920, 1,720 (560 - 640, 1,235 (660 - 740, 1,455
N (kg, lb)
- 1,632) - 1,874) - 1,874) - 1,411) - 2,029) - 1,411) - 1,632)

Inspection and Adjustment

CLUTCH PEDAL
Unit: mm (in)

ZD30DDTi TB45E TD42 TB48DE TD42 TB45S

Applied model
H/T Wagon Wagon Pickup

Pedal height 195 - 205 200 - 210 200 - 210 195 - 205 200 - 210 185 - 195
“H*” (7.68 - 8.07) (7.87 - 8.27) (7.87 - 8.27) (7.68 - 8.07) (7.87 - 8.27) (7.28 - 7.68)

Pedal free play

“A” (at pedal 1.0 - 3.0 (0.039 - 0.118)
pad)
*: Measured from surface of melt sheet to pedal pad

CLUTCH BOOSTER
Unit: mm (in)

Output rod length “A” 1.30 - 1.55 (0.0512 - 0.0610)

Input rod length “B” 130 (5.12)

CL-6
 SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Cont’d)
CLUTCH DISC GI
Unit: mm (in)

ZD30DDTi TB45E TD42 TB48DE TD42 TB45S

MA
Applied model 275 300 275

H/T and Wagon Wagon Pickup

Wear limit of facing

EM
0.3 (0.012)
surface to rivet head

Runout limit of facing 1.3 (0.051)

LC
Distance of runout
check point (from 132.5 (5.22) 145 (5.71) 132.5 (5.22)
the hub center) EC
Maximum backlash of
spline (at outer edge 1.0 (0.039) 1.5 (0.059) 1.2 (0.047) 1.0 (0.039)
of disc) FE
CLUTCH COVER
Unit: mm (in)

ZD30DDTi TB45E TD42 TB48DE TD42 TB45S

Applied model 275 300 275
MT
H/T and Wagon Wagon Pickup

Diaphragm spring height “A” 44 - 46 (1.732 - 1.811)

AT
Uneven limit of diaphragm
0.7 (0.028) 1.0 (0.039) 0.7 (0.028)
spring toe height

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

SE

IDX

CL-7