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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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HND058U
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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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This method is applicable to the coordinated assembly of friction discs (driven discs) and pressure plates for mainstream dry clutches of Hino heavy-duty trucks. It adheres to the four core principles of correct orientation, precise centering, oil-free friction surfaces, and torque compliance to ensure smooth engagement, thorough disengagement, and guaranteed service life. For hydraulic/CSC systems and self-adjusting pressure plates, follow the requirements specified in the vehicle-specific workshop manual.
Park the vehicle on flat, hard ground; engage the parking brake and secure the wheels with wheel chocks. Disconnect the negative battery terminal.
Allow the engine and transmission to cool down to ≤40℃. Support the transmission with a specialized jack plus safety stands. Never use a hydraulic jack alone for load-bearing purposes.
Cleaning and Pre-Treatment (Oil Prohibition is Essential)
Thoroughly clean the flywheel, pressure plate, and both sides of the driven disc with degreaser or isopropyl alcohol. Wipe dry and operate with gloves on. Never touch friction surfaces with bare hands.
Apply a thin coat of copper grease to the driven disc spline bore and transmission input shaft splines (for splines only; do not allow grease to contaminate friction surfaces). Derust and apply anti-rust agent to alignment pin holes to ensure smooth insertion and removal.
Orientation Confirmation (Reverse Installation Forbidden)
Follow Markings: The side marked “Gearbox Side” must face the transmission; the side marked “Flywheel Side” must face the flywheel.
For Unmarked Discs: The side with protruding damping springs or longer spline hub faces the transmission (markings take priority).
Consequences of Reverse Installation: Incomplete disengagement, difficult gear shifting, and rapid friction disc burnout.
Precise Centering (Coaxial Alignment is Critical)
Install the flywheel alignment pins in place. Center the driven disc and insert the alignment tool: one end into the flywheel center bearing hole, the other through the driven disc spline bore.
Ensure the driven disc rotates freely without deviation, with uniform peripheral gap (≤0.1mm) between the disc and flywheel contact surface. Do not install without an alignment tool.
Pressure Plate Assembly and Diagonal Step-by-Step Tightening (Prevent Deformation)
Align the pressure plate with the flywheel alignment pins and place it over the driven disc. Insert new bolts (thread locker application recommended).
Three-Step Tightening Process:
Prohibitions: Do not use an air impact wrench for direct tightening; do not tighten in a non-diagonal sequence.
For Self-Adjusting Pressure Plates: Compress the diaphragm spring with a specialized tool first. Unlock the self-adjusting mechanism after the pressure plate fits the driven disc, then perform final tightening.
After tightening, gently wiggle the alignment tool to confirm no jamming, then pull it out slowly.
Hand-tighten all bolts until they make contact with the pressure plate (no additional torque applied).
Pre-tighten bolts diagonally to 50% of the nominal torque.
Final-tighten bolts diagonally to Hino OEM standard torque (28–35 N·m common for heavy-duty trucks; refer to the vehicle manual for exact values).
Release Mechanism Installation and Transmission Reinstallation
Release Bearing/CSC: Apply specified high-temperature grease to contact surfaces; ensure smooth rotation. Pre-install hydraulic CSC and check for leaks.
Transmission Docking: Lift the transmission slowly and dock it with the engine, ensuring the input shaft slides into the splines smoothly. Do not force docking with a pry bar.
Tighten transmission mounting bolts diagonally to nominal torque. Reconnect hydraulic lines/cables, wiring harnesses, and drive shafts. Perform a complete bleed of the hydraulic system.
Static Inspection: The transmission input shaft rotates smoothly without resistance; the release fork presses evenly and returns quickly; no excessive local gaps exist between mating parts.
Dynamic Testing: Gears engage easily at idle without grinding; the vehicle starts smoothly without shuddering or slipping; gear shifts are smooth during road tests with clear engagement points; stable hill starts.
Break-in Period: Avoid half-clutch starts and heavy-load hill climbing for the first 500km to allow sufficient break-in.
These precautions apply to the coordinated assembly process of friction discs (driven discs) and pressure plates for mainstream dry clutches of Hino heavy-duty trucks. They focus on five core priorities: orientation compliance, cleanliness control, centering accuracy, torque specifications, and system compatibility, so as to avoid clutch shudder, slipping, incomplete disengagement, premature component failure and other faults caused by improper installation operations.
The side of the driven disc marked “Gearbox Side” must face the transmission; the side marked “Flywheel Side” must face the flywheel. Alignment must be strictly performed in accordance with the markings, and any reverse assembly is prohibited.
For unmarked driven discs, the judgment criteria are as follows: the side with protruding damping springs or the longer spline hub faces the transmission. In the end, the requirements specified in the Hino original equipment manufacturer (OEM) service manual shall prevail.
Reverse installation of the driven disc will directly lead to insufficient clutch release stroke, gear grinding during shifting, and rapid burnout of friction linings. In severe cases, it will damage the pressure plate diaphragm spring, transmission input shaft splines and release mechanism, resulting in high maintenance costs.
References：
The two documents you referred to—Installation Method for Hino Clutch Friction Disc and Special Precautions—are original compilations developed during our prior discussions. They are not verbatim excerpts from any single public standard or official Hino service manual. However, the core technical basis and source verification are as follows:
Official Hino Workshop ManualCovering mainstream Hino heavy-duty truck models, this manual provides core operational principles and parameters, including clutch alignment tool positioning, diagonal step-by-step bolt tightening, torque specifications, as well as operation procedures for self-adjusting pressure plates and hydraulic CSC. It serves as the fundamental basis for ensuring technical accuracy.
Universal Industry Maintenance Standards and Guidelines from Leading BrandsStandardized procedures—such as strict oil contamination control on friction surfaces, applying a thin coat of copper grease exclusively to splines, and hydraulic system bleeding—are integrated from installation guidelines for clutch assemblies produced by Hino Genuine Parts, Schaeffler, Valeo and other major manufacturers. These steps are suitable for on-site implementation in professional repair workshops.
Customized Compilation Based on Dialogue HistoryThe above-mentioned official principles and industry standards have been reorganized and refined into a logical structure: safety preparation → core installation steps → commissioning and acceptance → special precautions. Practical details such as tool lists, inspection thresholds, and failure consequences have been added to form the structured Chinese document you currently use, which is optimized for on-site application.
Submit a request to an authorized Hino dealer or service center for the Workshop Manual corresponding to your vehicle’s model and production year. Refer to the chapter titled Clutch Pressure Plate Installation to obtain precise torque values, clearance specifications, specialized tool lists, and illustrated step-by-step instructions.
When purchasing a genuine Hino clutch assembly, an installation guide is usually included in the package. This guide contains critical information such as orientation markings, lubrication points, and bolt tightening sequences.
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