The following is our ZNDmotor’s guidance regarding how to install new clutch kit.
Something that you should do before installation
1. Does the hydraulic system work properly?
2. Are there any oil leak and red dust after old clutch is removed?
3. Are there any cracks on clutch release fork?
4. Are there any signs of stretch on clutch cable?
5. Is release bearing guide tube worn?
6. Are there anything wrong with spigot bearing or pilot bush? If there is, you need to replace it.
7. Are there any shipping damages on clutch?
Please pay attention to the issues mentioned above, which must be addressed prior to installing a new clutch.
1. Please note shaft splines, clutch disk and bell housing when installing clutch.
(1) You need to clean gearbox main drive shaft splines and make sure clutch disc can slide on the shaft freely.
(2) You need to grease shaft splines lightly with high temperature grease. If too much grease is used, clutch plate or disc might be contaminated.
(3) You need to clean bell housing by doing these: remove grease, dust and worn clutch fibers.
2. Please make sure bearing carrier can work properly.
(1) In order to slide bearing carrier smoothly, the outside diameter of the tube should be lubricated lightly.
(2) After installing the bearing on clutch release fork, you need to check it to ensure it is securely placed. You need to move the fork forwards and backwards to ensure nothing falls, and then you can reinstall the gearbox.
3. Please make sure pressure plate and clutch disc are aligned correctly.
(1) You need to place clutch cover pressure plate assembly on the clutch disc. In the meanwhile, you need to make sure the disc is centered to the pressure plate precisely for proper alignment.
(2) You need to apply pressure.
(3) You need to tighten or torque bolts in a diagonal pattern.
Please remember DO NOT install a clutch cover assembly by air tools. Incorrect torquing down of the bolts may be likely to lead to an uneven pattern and dislodgment of lever strut from pressure plate casting. Hence, bolts should be torqued based on manufacturer’s specification.
(4) You need to attach pressure plate to the flywheel securely.
(5) You need to ensure diaphragm tips are in a parallel or slightly upward position.
4. Finishing up
(1) You need to reinstall gearbox.
(a) do not bend clutch disc; (b) do not hang gearbox off clutch disc; (c) use force to align gearbox shaft.
(2) You need to tighten bell housing bolts and make sure bell housing dowels are in correct position.
(3) You need to clean to guarantee there is no dirt or foreign material between engine’s mating surfaces and bell housing.
(4) You need to do clutch adjustments to vehicle manufacturer’s specifications. You also need to reset clutch master cylinder push rod to make sure comfortable pedal release position.
(a) clutch taking up as close as possible to the floor can prevent clutch shudder; (b) installation of new clutch could change diaphragm tip’s position.
(5) You need to check clutch cable unless you are able to obtain disengagement when a new clutch is installed.
(6) You need to replace the cable and figure out where disengagement problem comes from.
(7) You need to ensure there is no air in the system and there is nothing that blocks compensating port if it is a hydraulic clutch start by checking clutch master cylinder and slave cylinder. This is vital to obtain maximum travel for disengagement.
(8) You need to take your vehicle a road test.
Hopefully, our ZNDmotor’s guidance regarding installing new clutch kit is useful and helpful for you guys. Still confused? Do not hesitate to contact us right now !!!