Installation Method of Clutch Friction Disc for KAMAZ Trucks

Preparations

Vehicle Preparation

1. Turn off the engine and let it cool down completely.

2. Engage the parking brake and shift the transmission to neutral.

3. Disconnect the negative terminal of the battery.

4. Hoist the vehicle frame and support it securely; remove the transmission assembly to expose the flywheel and clutch chamber.

Tools and Spare Parts

• Tools: Torque wrench, socket set, clutch centering alignment shaft, wire brush, degreaser, high - temperature lubricating grease, copper paste.

• Spare Parts: New friction disc, pressure plate, release bearing, bolts/lock washers, seals.

Marking

Installation Steps (Single - Plate Clutch as an Example; Double - Plate Clutch Requires Additional Intermediate Pressure Plate and Positioning)

1. Cleaning and Inspection

• Flywheel and Pressure Plate Friction Surfaces: Thoroughly remove oil stains and rust with a degreaser. Check for warping, heat spots or grooves; machine or replace the parts if necessary.

• Input Shaft Splines and Pilot Bearing: Clean the splines and apply high - temperature lubricating grease. Fill the pilot bearing with grease and verify that it rotates smoothly without abnormal noise. Ensure the spline fit is free - moving without jamming or excessive looseness.

• New Friction Disc: Confirm that the model matches the vehicle specifications. The side with damping springs/protrusions should face the pressure plate, and the flat side should face the flywheel. Apply a thin layer of grease to the spline bore and wipe off any excess to prevent oil contamination of the friction surfaces.

2. Centering and Pre - installation

• Insert the centering alignment shaft through the flywheel pilot bearing and the friction disc spline bore to ensure the friction disc is centered, which prevents jamming of the transmission input shaft during installation.

• Reinstall the pressure plate/clutch cover assembly according to the original alignment marks. Insert the bolts and hand - tighten them to ensure the pressure plate fits flatly against the flywheel.

3. Diagonal Uniform - Load Tightening

• Tighten the bolts in 2–3 rounds following a diagonal alternating sequence to the torque specified by the manufacturer (the typical torque range for KAMAZ is 45–65 N·m; refer to the vehicle manual for exact values).

• Never use an air impact wrench for one - time violent tightening, as this may cause pressure plate deformation and uneven stress on the diaphragm spring.

• Remove the centering alignment shaft and check the axial runout and rotational flexibility of the friction disc.

4. Assembly and Adjustment of the Release Mechanism

• Install the release bearing and release fork. Apply high - temperature lubricating grease to the bearing to ensure smooth movement without jamming. Check that the heights of the diaphragm spring fingers are consistent and make fine adjustments if required.

• Reinstall the transmission: Align the input shaft with the friction disc spline bore, push it in slowly, and tighten the transmission - to - engine connecting bolts to the specified torque. Connect the clutch master cylinder/booster, oil pipes/air pipes, bleed the hydraulic/pneumatic system, and adjust the clutch pedal free travel and release clearance.

Installation Precautions for KAMAZ Clutch Friction Disc

1. Strict Prohibition of Reverse InstallationThe side of the new friction disc with damping springs/protrusions must face the pressure plate, and the flat side must face the flywheel. Reverse installation will directly lead to incomplete clutch disengagement, difficult gear shifting, abnormal noise during start-up, and even friction disc burnout in severe cases.
2. Absolute Cleanliness of Friction SurfacesThe surfaces of the flywheel, pressure plate and friction disc must be free of residual oil, iron filings or dust, and should be thoroughly wiped with a degreaser before installation. Oil contamination will cause clutch slipping, while iron filings will accelerate the wear of friction surfaces and lead to start-up judder.
3. Standard Operation for Bolt Tightening

• The connecting bolts between the clutch cover and the flywheel must be tightened in 2–3 rounds following a diagonal alternating sequence to the torque specified by the manufacturer (the typical torque range for KAMAZ is 45–65 N·m; refer to the vehicle manual for exact values).

• Never use an air impact wrench for one-time violent tightening, as this will cause pressure plate deformation and uneven stress on the diaphragm spring, resulting in unsmooth clutch engagement and abnormal disengagement noise.

• Before installation, check that the bolts and lock washers are intact without thread slipping or deformation.

4. Mandatory Use of Centering Alignment ShaftDuring the pre-installation phase, insert the alignment shaft through the flywheel pilot bearing and the friction disc spline bore to ensure accurate centering of the friction disc. Without the alignment shaft, the transmission input shaft cannot be installed smoothly, and forced assembly will damage the splines and the friction disc positioning structure.
5. Precise Control of Lubrication Points

• Apply high-temperature lubricating grease to the transmission input shaft splines, flywheel pilot bearing and release bearing. The lubricant should be applied thinly and evenly to prevent excess grease from splashing onto the friction surfaces.

• A small amount of copper paste can be applied to the contact area between the diaphragm spring fingers and the release bearing to reduce wear and abnormal noise.

6. Clearance Adjustment of the Release MechanismAfter installing the release bearing and release fork, check that the heights of the diaphragm spring fingers are consistent, with the error controlled within the range allowed by the manufacturer (usually ≤ 0.5 mm). After reassembly, adjust the clutch pedal free travel and release clearance to ensure thorough disengagement, smooth engagement and no slipping during semi-engagement.
7. Special Requirements for Double-Plate Clutches

• The two friction discs must be installed in the same orientation, with the damping spring side facing the corresponding pressure plate.

• The intermediate pressure plate must be positioned by limit pins or adjusting bolts to ensure uniform release clearance between the two friction discs, preventing single-disc loading and uneven wear.

8. Component Inspection Before Assembly

• Check the flywheel end face runout; if it exceeds the standard, the flywheel must be turned or replaced. Inspect the pressure plate for heat spots and cracks, and check the diaphragm spring for fatigue fractures.

• Confirm that the model of the new friction disc matches the original vehicle, and that the damping springs are free of looseness and abnormal noise.

9. Safety and Operation Specifications

• Turn off the engine and disconnect the negative terminal of the battery. Hoist the vehicle with a dedicated lift and support it securely; never use a jack alone for supporting during operation.

• When reinstalling the transmission, push it in slowly. Avoid prying hard to prevent damage to the input shaft or friction disc.

10. Key Points for Test Run and Acceptance

• Fully bleed the hydraulic/pneumatic booster system to ensure no air bubbles remain and the pedal returns to its normal position smoothly.

• Verify the following during road testing: no judder during start-up, smooth gear shifting, no slipping during heavy-load climbing, and no abnormal disengagement noise when idling in neutral.

References：

Supplementary Notes

1. Source Nature

   This guide is an integration of standardized maintenance procedures and KAMAZ model-specific characteristics. It covers industry-general key points such as cleaning, centering, diagonal tightening and clearance adjustment, while being adapted to the structural features and common maintenance practices of KAMAZ trucks.
2. Official Basis

   The original KAMAZ maintenance manuals (e.g., manuals for KAMAZ 5320/65115 series) contain more precise parameters including torque values, clearance data, disassembly and assembly steps as well as part numbers. However, such official manuals are generally available only through authorized dealers or official channels. The content provided can serve as a general guide for on-site operation, but it must be cross-checked with the parameters specified in the vehicle-specific manual in the end.
3. Suggestions for Distinction

   If you need the exact verbatim citation source, I can assist in searching for the corresponding KAMAZ original manual number or chapter. If the content is only for maintenance operations, it is recommended to confirm key parameters such as torque and clearance according to the vehicle model manual to avoid malfunctions caused by model differences.