CLUTCH PLATE 41100-4D030 411004D030 41100-4D030 FORtruck

I. Core Preparation (Safety and Tools)

• Park the vehicle on level ground, engage the parking brake, and secure the front and rear tires with wheel chocks.

• Disconnect the negative (-) battery terminal (to prevent accidental starting).

• Heavy-Duty Clutch Aligning Tool: Must perfectly match the transmission input shaft splines and the crankshaft pilot bearing bore.

• Torque Multiplier: Truck pressure plate bolts require extremely high torque (typically 500-1000 N·m or more), which cannot be achieved with a standard torque wrench.

• Guide Mandrel / Protective Sleeve: Prevents damage to the input shaft oil seal during transmission installation.

• Brass Drift / Rubber Mallet: Used for light tapping during alignment. Strictly prohibit directly striking the friction disc with a steel hammer.

II. Critical Pre-Installation Checks

• Runout: Use a dial indicator to check the runout of the flywheel friction surface. If it exceeds the standard (typically >0.2mm), the flywheel must be machined or replaced; otherwise, it will cause launch shudder.

• Cleanliness: Oil, rust, and old friction material dust must be completely removed from the flywheel surface.

• If equipped with a pull-type clutch, check the height of the pressure plate diaphragm spring release fingers. If they are uneven, adjust them to the standard height (typically with an error <0.5mm); otherwise, incomplete disengagement will occur.

• Must be replaced. Truck clutches operate under heavy loads; an old bearing will cause input shaft wobble, leading to friction disc burnout.

III. Mechanical Installation Steps (Single/Dual Disc General)

• Point 1: Friction disc splines (ensures free sliding of the transmission input shaft).

• Point 2: Release bearing sliding sleeve / quill (if push-type).

• Point 3: Release fork pivot points and spherical plain bearings (if mechanical release).

• Taboo: Strictly prohibit grease from contacting the friction surfaces of the disc! Once contaminated, the clutch will burn out.

• Push-Type Clutch: The side marked "Flywheel Side" faces the flywheel. Typically, the side with the shorter or flatter damper springs faces the flywheel.

• Pull-Type Clutch: The side marked "Gearbox Side" faces the transmission. Typically, the side with the longer or protruding damper springs faces the transmission.

• Dual-Disc Clutch: The orientation of the discs on both sides of the intermediate plate must strictly follow the instructions; usually, one disc is installed "normally" and the other "inverted."

• Place Pressure Plate: Position the pressure plate (or intermediate plate) onto the flywheel, aligning with the dowel pins.

• Place Friction Disc: Insert the friction disc into the center of the pressure plate.

• Insert Aligning Tool: Pass the aligning tool through the friction disc splines and into the crankshaft pilot bearing bore.

• Calibration: Press the friction disc lightly by hand and tap the center of the tool with a brass drift to ensure the friction disc is absolutely parallel to the flywheel and the splines are smooth.

• Pre-tightening: Screw in all bolts by hand to ensure the pressure plate is seated against the flywheel.

• Cross Tightening: Must be strictly performed in a crisscross/diagonal sequence.

• Step-by-Step Tightening:

• 1st Pass: Tighten to 50% of the specified torque.

• 2nd Pass: Tighten to 90% of the specified torque.

• 3rd Pass: Use a torque multiplier to tighten by the specified angle (e.g., 90°) or to the final torque value.

• Reference Torque (Check specific model):

• Sinotruk / Weichai Series: Typically 650 - 800 N·m.

• Imported Trucks (Volvo / Scania): Typically 900 - 1100 N·m.

• Remove Tool: After bolts are fully tightened, check if the aligning tool can still rotate easily. If rotation is difficult, it indicates the splines are misaligned; the bolts must be loosened and realigned.

IV. Special Steps for Dual-Disc Clutches

1. Intermediate Plate Limiting: After installing the first friction disc and the intermediate plate, check the intermediate plate travel (release clearance).

2. Install Second Disc: Insert the second friction disc (pay attention to orientation), then install the pressure plate cover.

3. Adjust Release Travel: After installation is complete, the release bearing clearance must be adjusted to ensure all friction discs disengage completely when the clutch pedal is depressed fully.

I. Bolt Tightening: The "Line Between Life and Death"

• Note: Truck pressure plate bolts typically require 600-1000 N·m of torque. Standard breaker bars cannot guarantee precision and can easily slip, causing injury.

• Requirement: A torque multiplier with a torque wrench interface must be used.

• Consequence: Insufficient torque will cause bolts to break or loosen under high loads, triggering a clutch explosion; excessive torque may shear the bolts.

• Note: For high-end models like Scania and Volvo, pressure plate bolts are often plastic-region bolts requiring tightening "to a specific torque and then rotating a specific angle (e.g., 90°)."

• Source: Always consult the vehicle's Workshop Manual.

II. Lubrication: "Absolute No-Go Zones" vs. "Necessary Special Zones"

• Strictly Prohibited: Both sides of the friction disc, the flywheel surface, and the pressure plate surface.

• Consequence: Even a single drop of oil causes clutch slip ("burning the disc"). If contamination occurs accidentally, it must be thoroughly cleaned with solvent and dried.

I. OEM Core Sources (Factory Service Manuals / TSBs)

II. Component Manufacturer Specifications (Luk/Sachs/Valeo)

• Search Path: Luk/Sachs Service Guide → Heavy-Duty Clutch Installation → Mechanical Checks

• Core Content: Orientation markings for dual-disc friction plates, Spline lubrication "No-Go/Special Zones," Aligning tool model matching table

• Access: Brand official website technical support pages, Authorized dealer technical documentation.

• Core Parameters: High-temperature grease model for release bearings, Guide sleeve fit clearance

• Access: Instructions included in Valeo original parts packaging, Dealer technical documents.

III. Industry Standards and International Norms