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Type :
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Clutch pressure plate
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Specification :
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Outer 180mm Inner 125mm
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Pulley :
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18T
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Brand :
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NUOJIN
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Number :
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22400-55F80
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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 a Suzuki clutch friction disc must follow the core principles of correct orientation, precise centering, diagonal and step-by-step bolt tightening, proper lubrication, and post-installation inspection to ensure smooth engagement, complete disengagement, and freedom from jitter or slippage. Below are the general installation steps and key specifications; refer to the vehicle’s service manual for model-specific details.
Park the vehicle on a level surface, engage the parking brake, shift to neutral, and disconnect the negative battery terminal to prevent accidental engine startup.
Securely support the vehicle with a lift or reliable jack; place an oil pan under the transmission to collect drained transmission fluid.
Friction disc: Ensure the friction surface is free of oil contamination, rivets are tight, rivet sinkage is ≥0.3mm, and the spline fits smoothly on the input shaft without binding.
Pressure plate: Verify the surface is flat (no burning, cracks, or warpage), the diaphragm spring has uniform elasticity, and height variation is ≤0.5mm.
Flywheel: Remove oil, rust, and debris from the surface with a clean cloth to ensure full contact with the pressure plate; inspect the flywheel ring gear and pilot bearing, replacing them if necessary.
Release bearing: Confirm it rotates freely without noise or binding; apply grease to the inner bore.
Confirm orientation: The torsion damper side of the friction disc faces the pressure plate (usually marked “FLYWHEEL SIDE”—verify before installation). For example, on Suzuki Alto models, the side labeled “FLYWHELL SIDE” must face the flywheel.
Spline lubrication: Apply a small amount (approximately 0.2g) of Suzuki-specified grease evenly to the friction disc spline hub and transmission input shaft splines (avoid over-greasing to prevent slippage); also lubricate the release bearing inner surface and release fork contact points.
Center alignment: Insert the alignment tool into the flywheel pilot bearing, then slide the friction disc onto the tool to ensure concentricity with the flywheel and input shaft, preventing misalignment during installation.
Align marks: Match the locating pins and assembly marks on the clutch cover and flywheel (mark them manually if no factory marks exist) to ensure balance and correct positioning.
Bolt pre-tightening: Install the pressure plate mounting bolts by hand until snug to avoid uneven initial loading.
Diagonal step-by-step tightening: Use a torque wrench to tighten the bolts in a diagonal pattern in 2–3 stages to the model-specific torque specification (typically 14.7–21.6N·m for gasoline models, 11.8–14.7N·m for diesel models—always refer to the service manual) to prevent pressure plate deformation.
Mount the release bearing to the release fork, ensuring it slides freely without binding; apply grease (approximately 0.3–0.5g) to the contact point between the fork and bearing.
Install the release fork assembly, ensuring proper contact between the fork and bearing, correct installation of the return spring, and smooth movement.
Clean the transmission input shaft splines and apply a small amount of grease; slowly slide the transmission onto the engine, ensuring the input shaft fully engages the friction disc spline hub without binding.
Install the transmission mounting bolts, tightening them in a diagonal pattern in stages to the specified torque; reconnect the driveshaft, shift linkage, clutch hydraulic line (if applicable), and other components.
Hydraulic clutch: Adjust pedal free travel via the master cylinder or slave cylinder pushrod (standard range: 15–25mm—refer to the service manual for model-specific values).
Mechanical clutch: Adjust the cable length to maintain the specified clearance between the release bearing and diaphragm spring, ensuring smooth pedal return.
Startup test: Start the engine and test the clutch pedal at idle: Ensure complete disengagement when pressed and smooth engagement when released, with no noise, jitter, or slippage.
Gear shift test: Shift through all gears to verify smooth operation without grinding or binding.
Road test: Test acceleration, gear shifts, and hill climbing at low speeds to confirm stable clutch engagement with no abnormalities.
General Rule
The torsion damper side (spring side / side marked “FLYWHEEL SIDE”) of the friction disc must face the flywheel end, and the side marked “GEARBOX SIDE” must face the transmission/pressure plate; reverse installation is strictly prohibited.
For Suzuki Alto models: The side of the friction disc printed with “FLYWHEEL SIDE” must be closely attached to the flywheel.
For Suzuki Vitara models: If there is no mark, it can be judged by the spline hub step—the step side faces the pressure plate, and the damper spring side faces the flywheel.
Consequence Warning
Incorrect orientation will cause severe jitter during clutch engagement, incomplete disengagement, rapid burnout of the friction disc, damage to the pressure plate diaphragm spring in a short period of time, and abnormal wear of the transmission input shaft splines. In severe cases, the entire transmission component set may need to be replaced.
Tool Requirements
A Suzuki-specific clutch alignment tool must be used (e.g., 09924-17811 for compact vehicles, 09924-17811 for mid-size vehicles); manual centering based on experience is prohibited. Custom-made tools must ensure a coaxiality error ≤ 0.05mm and full compatibility with the input shaft splines.
Operation Specification
Fully insert the alignment tool into the flywheel pilot bearing, slide the friction disc onto the tool, and confirm that the friction disc end face is parallel to the flywheel end face and that there is no gap between the spline and the tool before installing the pressure plate. Do not strike the friction disc during installation to prevent deformation of the damper spring.
Consequence Warning
Centering deviation will make it impossible to assemble the transmission smoothly, or cause clutch abnormal noise, jitter, and early spline meshing failure during operation. In severe cases, it will lead to uneven wear and scrapping of the friction disc, and even breakage of the transmission input shaft.
References：
This document on critical precautions for Suzuki clutch friction disc installation is a compiled and refined summary based on the Suzuki Official Service Manual as the core reference, supplemented by third-party repair documents and forum resources. Specific source details are as follows:
It provides key technical parameters and operational specifications, including:
Dedicated clutch alignment tools (09924-17811/09924-35010)
Genuine specified grease (SUZUKI MOLY 99000-25010)
Diagonal, step-by-step tightening torque for pressure plate bolts (14.7–19.6N·m for compact gasoline models, 19.6–24.5N·m for mid-size/four-wheel drive models, 11.8–14.7N·m for diesel models)
Standard clutch pedal free travel (15–20mm)
For model-specific torque values and procedures (e.g., Alto/Swift, Vitara/S-Cross, Jimny), refer to the corresponding vehicle service manual.
This text is a systematically integrated general technical summary and does not directly quote a single source. It takes the official service manual as the core and verifies details with third-party documents to ensure accuracy and practicality. Installation details vary across different models (e.g., Alto/Swift, Vitara/S-Cross, Jimny). For actual operations, always refer to the official service manual corresponding to the specific vehicle model.
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