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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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HND009
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Quality :
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Remanufacture
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Delivery time :
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10 day
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The installation of the clutch friction disc for HINO heavy-duty trucks shall be centered on the principles of cleanliness and alignment, correct orientation, torque compliance, standardized lubrication, and complete disengagement. The operation must be performed in accordance with the original factory maintenance manual, applicable to mainstream HINO models such as the 700 and 500 series. For key torque values and clearance specifications, refer to the maintenance manual of the corresponding model. The following is the complete procedure and key points:
Park the vehicle securely, engage the parking brake, and shift to neutral. Disconnect the negative cable of the battery and release the air/hydraulic pressure in the clutch booster cylinder to prevent accidental activation.
Mark the alignment positions between the flywheel and clutch cover, as well as between the pressure plate and cover, to ensure reinstallation in the original position and avoid damaging the dynamic balance.
Essential Tools: Torque wrench, socket set (commonly 19–24mm), clutch centering mandrel (specialized tool), flathead/Phillips screwdrivers, cleaning cloths, high-pressure air gun, high-temperature resistant grease (for splines and release bearing), thread-locking adhesive (if required).
Replacement Parts: New friction disc (driven plate), pressure plate assembly, release bearing, pilot bearing (recommended for simultaneous replacement), fixing bolts (comply with manual specifications; some are single-use only).
Friction Disc: Verify that the model matches the vehicle requirements. Ensure the friction surface is free of oil contamination, burn marks, and exposed rivets. Check the spline hub for wear and cracks; confirm smooth, non-jamming engagement with the transmission input shaft splines.
Flywheel/Pressure Plate: Clean the flywheel end face and pressure plate working surface to remove oil, rust, and wear debris. Inspect the flywheel ring gear and pressure plate diaphragm spring for deformation or fractures; ensure all release fingers are at the same height.
Pilot Bearing/Release Bearing: New bearings should rotate without abnormal noise and be pre-lubricated with grease. Replace old bearings if there is looseness or abnormal noise during rotation.
Replace the pilot bearing in the center of the flywheel and fill 1/2–2/3 of its cavity with high-temperature resistant grease. Apply a thin, even layer of grease to the inner wall of the driven plate spline hub; do not over-lubricate to prevent grease from contaminating the friction surface.
Insert the centering mandrel through the flywheel pilot bearing and the center hole of the driven plate to ensure coaxial alignment between the driven plate and the flywheel.
The side of the friction disc marked “FLYWHEEL SIDE” must face the flywheel; the side with the protruding hub (longer spline section) must face the transmission. Mounting the disc in reverse will cause complete clutch disengagement failure and severe vibration during vehicle startup.
Slide the driven plate onto the centering mandrel and place it gently against the flywheel end face, ensuring the splines are perfectly aligned with the transmission input shaft without deflection.
Align the pressure plate assembly with the pre-marked positions on the flywheel and clutch cover, then place it over the driven plate. Insert the fixing bolts and hand-tighten them initially to prevent thread seizing.
Use a torque wrench to tighten the bolts in 2–3 stages following a diagonal sequence to the torque specified in the manual (common torque range for HINO heavy-duty trucks: 80–120 N·m, subject to the specific model manual). Never tighten the bolts in a single step or use an air impact wrench, as this may cause pressure plate warping.
Remove the centering mandrel and check that the pressure plate fits evenly against the flywheel without warping.
Install the release bearing onto the release fork and apply grease to the contact points between the fork shaft and the bearing. Ensure the release bearing fits snugly against the diaphragm spring release fingers without jamming.
Assemble the clutch release fork and return spring, then adjust the free travel of the release fork to ensure the clearance between the release bearing and the release fingers complies with the manual specifications (typically 3–5 mm).
Connect the push rod of the clutch booster cylinder and adjust the stroke of the master/slave cylinders to ensure complete clutch disengagement when the pedal is depressed and smooth engagement when released.
No-Load Test: Start the engine, depress the clutch pedal, and test gear shifting for smooth engagement without jamming. Release the pedal and confirm that the clutch engages without slipping or abnormal noise.
Road Test: Verify that there is no vibration during heavy-load startup, no slipping during acceleration, and no drag during braking. Perform continuous gear-shifting tests to confirm complete clutch disengagement and smooth engagement.
Slippage: Check for oil contamination on the friction surface, verify pressure plate bolt torque, and inspect release clearance. Replace the friction disc and pressure plate if burn marks are present.
Abnormal Noise: Inspect the lubrication condition of the release bearing, pilot bearing, and splines; reassemble or replace components if necessary.
References：
The content below is divided into three sections—Official Core References, Industry and National Standard References, and Content Integration & Compilation Notes—to ensure the technical information is authoritative, compliant, and suitable for practical application scenarios.
HINO Original Factory Maintenance ManualsIncluding
Chassis Maintenance Manual for GAC HINO 700/500 Series (e.g., S1-HSSC01B) and
HINO 700 Series Service Manual. The core contents cover friction disc orientation markings, pressure plate bolt torque (typically 80–120 N·m), release clearance standards (3–5 mm), specifications for centering tool usage, and component replacement cycles. These manuals serve as the primary source of information, with clear requirements such as diagonal step-by-step tightening of pressure plate bolts and specified grease dosage for splines.
HINO Technical Service BulletinsThese bulletins provide supplementary installation specifications for friction discs on models operating under heavy-duty conditions or in special climates, including requirements for the simultaneous replacement of pilot bearings and release bearings, as well as precision standards for friction disc spline fitment.
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