Daihatsu Hijet — Clutch

Cable Specifications

Cable Adjustment

1. Locate the clutch cable adjuster where the cable enters the transmission bellhousing — there is an adjustment nut and a lock nut.
2. Loosen the lock nut. Turn the adjustment nut to increase or decrease pedal free play.
3. Measure free play at the clutch pedal pad. Target: 15 – 25 mm of travel before resistance is felt.
4. Tighten the lock nut once free play is set. Re-check the measurement after locking — the lock nut can pull it slightly.
5. Verify pedal deck height (floor to pedal pad at rest): 139 – 149 mm. If out of range, adjust the pedal stop bolt at the bracket.

Cable Replacement

1. Remove the clutch housing dust cover from the bellhousing.
2. Back off the adjustment nut fully to create slack in the cable.
3. Disconnect the cable end from the release fork inside the bellhousing.
4. Remove the two cable bracket retainer bolts. Lift up on the clutch pedal and pull the cable free from the pedal assembly.
5. Some models have a lock clip at the pedal end — release this before pulling the cable through.
6. Route the new cable in reverse. Clip the lock clip first, then attach to the fork.
7. Set cable free play to 15 – 25 mm and reinstall the dust cover.

Disk Inspection Limits

Disk & Pressure Plate Replacement

1. Remove the transmission.
2. Attach a flywheel holder tool to prevent rotation. Remove the six pressure plate bolts in a cross pattern and remove the pressure plate and disk.
3. Check flywheel runout with a dial gauge — limit is 0.10 mm. Inspect ring gear teeth for damage.
4. Apply 0.2 g of high-temp chassis grease to the input shaft spline. Keep grease off the friction material.
5. Use a clutch alignment tool to center the new disk in the flywheel, then set the pressure plate over it.
6. Install the six bolts and torque in a cross pattern to 185 ± 35 kg·cm. Remove the alignment tool.
7. Replace the release bearing. Lightly grease the release fork pivot point and the bearing contact surface.
8. Reinstall the transmission and set cable free play.

Parts