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Type :
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clutch plate
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Specification :
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Pulley :
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Brand :
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NUOJIN
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Number :
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Quality :
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new
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Delivery time :
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30 days
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The core of installing a Mazda clutch disc lies in strictly adhering to orientation positioning, coaxial alignment, phased cross - tightening of pressure plate bolts (25–33 N・m), lubrication of the pilot bearing and release mechanism, and adjustment of pedal travel and free play, so as to ensure smooth engagement and disengagement without jitter or abnormal noise. The following are the general procedures and key points (taking common Mazda models as examples).
Park the vehicle on a level surface, engage the parking brake, disconnect the battery, and drain the transmission fluid. Securely support the vehicle with a lift or jacks. Remove the engine splash guard, drive shafts/axles, and the transmission assembly (special pullers and socket wrenches are required).
Confirm that the clutch kit (clutch disc, pressure plate, release bearing) is compatible with the vehicle model (e.g., Skyactiv - specific models). Prepare tools including a torque wrench, alignment tool (SST), dial indicator, lithium - based grease, sandpaper/cleaner, etc.
Make assembly marks on the flywheel and clutch cover. Loosen the pressure plate bolts in a cross - pattern in multiple stages to release spring tension and prevent deformation. Remove the old clutch disc, pressure plate, and release bearing.
Flywheel: Polish/clean the surface. Check its flatness (runout ≤ 0.1 mm) and ensure there are no grooves, burn marks, or cracks. Minor wear can be repaired by grinding; if the wear is severe, turning or replacement is necessary.
Clutch Disc: The thickness of the new disc should be ≥ the specified value (e.g., ≥ 2 mm). Ensure the splines are undamaged and free of oil contamination. The side marked "Flywheel Side" should face the flywheel.
Pilot Bearing: Check if it rotates smoothly. Replace it and apply high - temperature grease.
Pressure Plate: Ensure the diaphragm spring has no fatigue or cracks, and the flatness deviation is ≤ 0.6 mm; replace the pressure plate assembly if it fails to meet the requirements.
Pass the alignment tool/SST through the splined hole of the clutch disc and the flywheel pilot bearing to ensure coaxiality and avoid installation misalignment.
Confirm the orientation of the clutch disc: the side marked "Flywheel Side" or the protruding end should face the flywheel, and the splines should mesh smoothly with the input shaft.
Place the pressure plate, align the assembly marks, insert the bolts, and pre - tighten them (do not fully tighten).
Phase 1: Pre - tighten all bolts in a diagonal sequence to leave room for adjustment.
Phase 2: Use a torque wrench to tighten the bolts in accordance with the vehicle - specific specifications (typically 25–33 N・m, e.g., for CX - 5/C66 MR models) to prevent eccentric load - induced deformation.
Install the release bearing. Apply lithium - based grease to the contact surfaces between the release fork and the bearing, and ensure the bearing has a free play of 1–2 mm.
Check that the release fork is not deformed, and the oil pipes/cables are securely connected without leakage.
Slowly push the transmission back into place, ensuring the input shaft is smoothly inserted into the splines of the clutch disc. Tighten the transmission mounting bolts to the specified torque.
Reconnect the clutch cylinder oil pipe/cable and the shift mechanism. Refill the transmission fluid and bleed the air from the system.
Adjust the total travel and free play (the common free play for Mazda models is 15–25 mm) to ensure complete disengagement when the pedal is fully depressed and a stable engagement point with no idle travel when released.
Start the engine and check for no abnormal noise when the pedal is depressed. Gear shifting should be smooth without impact.
Road Test: Test low - speed starts and gear shifts for smooth operation without jitter or abnormal noise. Ensure there is no slipping during rapid acceleration and no burning smell during half - engagement on steep slopes.
Re - inspection: After a 5–10 km road test, recheck the tightness of the pressure plate bolts, pipeline joints, and wiring terminals to ensure there is no looseness or leakage.
The installation of a Mazda clutch disc requires strict control over five key aspects: orientation positioning, torque specifications, lubrication protection, clearance adjustment, and component inspection to avoid faults such as jitter, slipping, and abnormal noise. The specific requirements are as follows:
The side of the clutch disc marked "Flywheel Side" must face the flywheel; the protruding end or the end with dense rivets shall correspond to the flywheel side. If there is no marking, the short end of the spline hub should face the pressure plate, and the long end should face the flywheel.
A special alignment shaft (SST) must be used during installation to pass through the spline hole of the clutch disc and the flywheel pilot bearing. This ensures coaxial alignment of the clutch disc with the flywheel and pressure plate, preventing damage to the input shaft splines or installation misalignment.
The pressure plate fixing bolts shall be tightened in 2–3 phases using a diagonal cross sequence, with the final torque strictly following the vehicle-specific specifications (typically 25–33 N·m; 28–30 N·m for Skyactiv models). Violent one-time tightening is strictly prohibited.
The use of an air impact wrench is forbidden, as it may cause pressure plate deformation and uneven stress on the diaphragm spring, leading to unsmooth clutch engagement or jitter.
Apply high-temperature lithium-based grease to the flywheel pilot bearing, the inner ring of the release bearing, and the contact surfaces between the release fork and the release bearing. The dosage should be sufficient to evenly cover the contact surfaces; excessive grease must be avoided to prevent it from splashing onto the clutch disc surface and causing slipping.
The clutch disc surface must be kept free of oil contamination and coolant. If contamination occurs accidentally, wipe it clean with a dedicated cleaner—do not grind the friction layer with sandpaper.
The release bearing must have a reserved free travel of 1–2 mm. Excessive free travel will result in incomplete disengagement, while insufficient free travel will cause continuous rotation and wear of the release bearing.
Adjust the clutch pedal free travel to meet the vehicle-specific standard (15–25 mm is common for Mazda models). Ensure the clutch can fully disengage when the pedal is pressed to the end, and the engagement point is stable with no idle travel when the pedal is released.
References：
The core information and authoritative basis for the Mazda clutch disc installation precautions are as follows:
Key Basis: Requirements including the phased diagonal cross-tightening of pressure plate bolts, positioning with a special alignment shaft (SST), flatness standards for flywheels and pressure plates, torque parameters (e.g., 28–30 N·m for Skyactiv models), clutch pedal free travel specifications (15–25 mm), and release bearing free travel (1–2 mm) are all derived from model-specific Workshop Service Manuals (WSM) and Electrical Troubleshooting Manuals (ETM) issued by Mazda, such as the official service manuals for Mazda 6, CX-5 and other models.
Specifications for special tools and operating procedures (e.g., phased loosening/tightening of bolts, alignment with a dedicated shaft) are extracted from Mazda's official maintenance standards. Manuals for certain Skyactiv models also clearly specify that the side marked "Flywheel Side" of the clutch disc must face the flywheel.
Standards for release mechanism clearance adjustment, hydraulic system bleeding, and component inspection (e.g., flywheel end face runout ≤ 0.1 mm, pressure plate flatness deviation ≤ 0.6 mm) are sourced from Mazda's after-sales technical training documents and maintenance operation specifications, which are formulated to ensure the disengagement/engagement performance and durability of the clutch system.
Requirements such as the selection of high-temperature lithium-based grease, protection of clutch discs against oil contamination, and prohibition of brute-force tightening with air impact wrenches are universal safety and technical standards for automotive clutch maintenance. These requirements are commonly found in industry maintenance manuals and installation guidelines released by leading clutch component manufacturers (e.g., LUK, EXEDY).
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