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Clutch Booster Assy 642-03080 For Mitsubishi Fuso FP FS FV Heavy Duty Truck – 70mm Air Clutch Servo
Product Overview
The clutch booster assembly (air clutch servo) carrying OEM number 642-03080 is a direct replacement for the clutch assist unit on Mitsubishi Fuso FP, FS, and FV series heavy-duty trucks, as well as other Fuso medium-duty chassis including Fighter, Super Great, and Canter models that share the same pneumatic clutch actuation architecture. It is also compatible with select ISUZU, HINO, NISSAN UD, and DAEWOO commercial vehicles.
Hydraulic-Over-Pneumatic Amplification for Heavy Loads
The clutch booster uses compressed air from the vehicle's air system to multiply the driver's pedal force. Hydraulic pressure from the clutch master cylinder triggers a relay valve, which admits air behind a large-area piston, generating up to 3-5 times the original input force. For a Mitsubishi Fuso FS hauling 25 tonnes, this amplification reduces clutch pedal effort from over 50 kg to 10-15 kg - a reduction of 70-80%, eliminating driver fatigue on long shifts.
70mm Diameter - Direct Fit for FP/FS/FV Chassis
The 70 mm body diameter matches the factory mounting bracket and clearance envelope on FP, FS, and FV trucks. The M14 × 1.5 air supply connector accepts the standard Fuso air line, and the M12 × 1.5 hydraulic inlet connects directly to the clutch master cylinder discharge pipe.
Corrosion-Resistant Aluminum Body
Unlike boosters with painted steel bodies that rust from road salt and brake fluid spills, this booster uses an aluminum body, which does not rust. The aluminum housing withstands under-chassis moisture, brine, and accidental fluid contamination, extending service life in harsh operating environments.
OE Match with ISO/TS16949:2002 Certification
The booster is manufactured in an ISO/TS16949:2002 certified facility - the globally recognized quality management standard for automotive components. Each production batch undergoes dimensional verification, seal integrity testing, and functional air-over-hydraulic pressure checks.
Cross-Referenced Against Multiple OE Numbers
The 642-03080 booster matches multiple interchange numbers including ME656040, 1-31800-140-0, 642-09008, 9700511900, and 628494AM.
Prevents Premature Clutch Disc and Pressure Plate Wear
A failing clutch booster that cannot fully disengage the clutch causes the clutch disc to spin against the flywheel while the driver attempts to shift, rapidly wearing the friction facing and overheating the pressure plate. Replacing a failed booster with this assembly restores full clutch disengagement travel, preventing secondary damage.
Quality Control & Verification
QC Item
Verification Method
Body casting integrity
Visual and X-ray inspection - no porosity, cracks, or voids
Cylinder bore finish
Air gauge and profilometer - 22.2 mm ±0.02 mm, Ra ≤ 0.4 µm
Thread verification
Go/no-go gauge for M14 × 1.5 and M12 × 1.5 ports
Seal leak integrity
Pneumatic pressure test - booster pressurised at 10 bar for 60 seconds, zero leakage
Hydraulic seal test
Pressurised with brake fluid simulator at 20 bar - no external seepage
Relay valve function
Air actuation test - valve opens at specified pilot pressure, closes cleanly
Mounting flange flatness
Dial gauge measurement - flatness within 0.1 mm
Paint / coating adhesion
Cross-hatch tape test per ASTM D3359 - minimum 4B rating
Full functional test (batch sampling)
Random 2-5% of each batch tested on air-over-hydraulic test bench under simulated pedal cycles (200 cycles at rated air pressure)
Installation & Maintenance Recommendations
⚠️ IMPORTANT: Clutch booster replacement involves the vehicle's compressed air system. Professional installation by qualified mechanics with access to appropriate bleeding and testing tools is strongly recommended.
Why this part fails (Mitsubishi Fuso heavy-duty specific considerations):
Diaphragm or seal deterioration: Over time, the internal rubber diaphragm and piston seals harden due to moisture contamination in the compressed air system.
Relay valve contamination: Dirt, debris, or oil from the compressor can enter the valve and cause sticking.
Hydraulic seal failure: The hydraulic piston seals may leak, allowing brake fluid to bypass and reducing pilot pressure.
External corrosion: Salt, moisture, and road chemicals corrode the body on non-aluminum units.
Recommended Replacement Indicators:
Symptom
Diagnosis
Clutch pedal extremely heavy, requires excessive force
Booster not generating pneumatic assist
Pedal feels spongy or inconsistent
Air in hydraulic system or internal seal leakage
Difficulty shifting gears, grinding noise when engaging
Incomplete clutch release
Air leakage from booster housing
Ruptured diaphragm or failed valve seal
Brake fluid leakage from booster hydraulic port
Worn hydraulic piston seal
Engine stalls when engaging clutch from stop
Clutch grabbing due to partial disengagement
Packaging & Supply
Individual packaging: Sealed in anti-rust VCI bag, foam-lined carton
Carton dimensions: 25 × 20 × 15 cm (approximate)
Net weight: Approximately 2.5-3.5 kg
Gross weight (with packaging): 3.0-4.0 kg
Master carton: 20 units per export carton (palletizable)
Lead time: 5-10 working days for stock orders; 20-25 days for production orders above 200 pieces
Minimum order quantity: 10 pieces (sample order available; single units negotiable)
Shipping methods: FedEx, UPS, DHL for samples; sea freight (LCL/FCL) from Shanghai, Ningbo, Guangzhou ports
H/S Code: 8708.30 or 8484.10
Quick Summary
The Mitsubishi Fuso clutch booster assembly 642-03080 is an OE-spec, 70 mm diameter hydraulic-over-pneumatic servo that reduces clutch pedal effort on FP, FS, and FV heavy-duty trucks. Its lightweight aluminum body resists corrosion, and ISO/TS16949 certified production ensures reliable performance under high-cycle conditions. One part number covers FP, FS, FV, Fighter, Super Great, and cross-platform trucks from ISUZU, HINO, and NISSAN.
Order a sample unit today - restore light, consistent clutch operation to your Fuso heavy truck.
Yimi(Guangzhou) Automotive Parts Co,Ltd
located in Guangzhou—the economic and transportation hub of Southern China—we are a specialized supplier and exporter with over 20 years of experience in the automotive parts industry. We focus on the production and sales of high-quality automotiv... Yimi(Guangzhou) Automotive Parts Co,Ltd
located in Guangzhou—the economic and transportation hub of Southern China—we are a specialized supplier and exporter with over 20 years of experience in the automotive parts industry. We focus on the production and sales of high-quality automotiv...
