Clutch kit clutch friction plate clutch plate HND047U、312502750 for Hino Truck

Pre-installation Preparation

Vehicle Fixation and Environment Arrangement

• Park the truck on a flat and solid surface, pull the handbrake tightly, and fix the wheels to prevent slipping. If it is necessary to lift the chassis, use a special heavy-duty jack to raise the vehicle body, then firmly support it with high-strength safety stands. Relying solely on the jack for operation is strictly prohibited.

• Ensure the working area is clean and dry to avoid contamination of installation components by dust and oil stains.

Tool and Component Preparation

• Prepare a complete set of wrenches, torque wrench, clutch alignment tool, high-temperature resistant clutch-specific grease, etc.

• Verify that the specifications of the new friction plate match the adapted model of the Hino truck; check that the new friction plate has no cracks, the rivets are not loose, and related components such as the clutch pressure plate and release bearing are free from deformation and excessive wear. Replace any damaged components synchronously.

• The new friction plate can be briefly soaked in transmission oil in advance to enhance subsequent operational smoothness.

Pre-cleaning and Component Inspection

1. Thoroughly clean the flywheel surface, pressure plate contact surface, and transmission input shaft splines to remove oil stains, iron filings, and impurities. This is a key step to avoid subsequent clutch slipping.

2. Inspect the friction surfaces of the flywheel and pressure plate: grind, repair, or replace them if there are scratches, warping, or other issues; test whether the release bearing rotates flexibly without abnormal noise and ensure the release fork is not deformed, confirming that all related components are in normal condition.

Core Installation Operations

1. Position the Friction Plate DirectionClarify the installation orientation of the friction plate: usually, the side with a boss faces the gearbox, and the side without a boss or marked "Flywheel Side" faces the flywheel. Do not install it in reverse, as this will result in incomplete clutch disengagement.
2. Apply Grease and PositionApply a thin layer of high-temperature resistant special grease to the spline hole of the clutch friction plate and the transmission input shaft splines to ensure smooth sliding after assembly. However, control the dosage to avoid excessive grease splashing onto the friction surface and causing slipping.Subsequently, insert a special alignment tool into the center of the friction plate to ensure alignment between the friction plate and the flywheel center, guaranteeing coaxiality.
3. Install the Pressure Plate and Tighten BoltsAlign the pressure plate with the installation position and fit it in place, then manually screw on all pressure plate fixing bolts.Next, use a torque wrench to tighten the bolts gradually in a diagonal pattern, controlling the force with reference to Hino's heavy-duty vehicle torque standards (specific values are subject to the vehicle manual). Avoid one-sided sequential tightening, which may cause pressure plate deformation and subsequent starting jitter.

Reassembly of Related Components

1. Install the release bearing and release fork assembly, and apply a thin layer of grease to the contact area between the release bearing and the release fork to ensure flexible separation movement.Check whether the heights of the release levers are consistent; adjust them to the standard height if necessary to ensure a normal separation stroke.
2. Remove the clutch alignment tool, and reinstall components such as the clutch housing and drive shaft in the reverse order of disassembly. Tighten the bolts at the connection points to the specified torque to prevent loosening during driving.

Post-installation Commissioning and Testing

1. For Hino trucks equipped with a hydraulic clutch, bleed the clutch system after installation: loosen the bleed screw, repeatedly press the clutch pedal 3-5 times, keep the pedal fully depressed until brake fluid flows out without bubbles, then tighten the bleed screw and install the protective cover.
2. After starting the vehicle: first test whether the clutch pedal free travel meets the vehicle model standards; then gently press the pedal to check if the clutch engages and disengages smoothly.The friction plate installation is qualified if there is no jitter during starting, no abnormal noise during driving, and no power transmission slipping during acceleration.

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I. Safety Operation Specifications (Heavy-Duty Vehicle-Specific Requirements)

Vehicle Fixation and Working Environment

• Must use special heavy-duty jacks and high-strength safety stands (rated load capacity ≥ 1.5 times the truck's curb weight). The support points must be aligned with the frame reinforcement areas; supporting on fragile areas such as fuel tanks and pipelines is prohibited. Wedge the wheels bidirectionally with wheel chocks to prevent slipping (heavy-duty vehicles have high inertia, leading to extremely high slipping risks).

• Reserve sufficient space in the working area to avoid stacking tools and components. If working under the vehicle, must wear a safety helmet and fasten a safety rope; solo operation is strictly prohibited (at least 2 people are recommended to cooperate for emergency rescue).

Tool and Equipment Specifications

• Must use a calibrated torque wrench (using ordinary wrenches to tighten by feel is prohibited). For key parts such as pressure plate bolts and clutch housing fixing bolts, strictly follow the torque specified in Hino's original factory manual (common torque for heavy-duty vehicles is 45-60N・m; specific values are subject to the vehicle model). Over-tightening will cause pressure plate deformation and bolt breakage, while under-tightening may lead to component detachment during high-speed driving.

• Prohibit the use of damaged or mismatched tools (e.g., using open-end wrenches instead of box-end wrenches) to avoid bolt stripping or component damage.

II. Component Protection and Cleaning Key Points

Friction Plate and Related Component Protection

• Handle the new friction plate with care; avoid impact and bending, and prevent the friction surface from being contaminated with oil stains and dust. If accidentally contaminated, wipe it clean with a special cleaning agent and let it dry before installation. Cleaning with gasoline or diesel is prohibited as it may corrode the friction material.

• It is strictly forbidden to apply grease, engine oil, or other lubricants to the friction surface of the friction plate. Only apply a thin layer of special grease to the spline hole and input shaft splines. Excessive grease splashed onto the friction surface will directly cause clutch slipping and failure to transmit power.

References：

1. General Guidelines for Clutch Installation of Heavy-Duty Commercial Vehicles

2. Accessory and Practical Maintenance Materials for Hino Trucks and Similar Heavy-Duty Vehicles