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Type :
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Clutch pressure 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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41200-2D220 41200-2D200
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Quality :
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NEW
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Delivery time :
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30DAY
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Installation Method of Dual-Clutch Pressure Plate for Hyundai Vehicles
For the installation of the dual-clutch pressure plate (matching the common DCT dual-clutch transmission) of Hyundai vehicles, strict compliance with process specifications is required to avoid clutch jitter, slipping or premature failure caused by improper operation. The specific steps are as follows:
I. Pre-installation Preparation
1. Inspection of Parts and Tools
Confirm that the model of the new pressure plate matches the vehicle type (the specifications of DCT pressure plates vary among different Hyundai models such as Elantra and Tucson). Check that the friction surface of the pressure plate is free from oil contamination, cracks and warping, and that the clutch diaphragm spring is free from deformation and rust.
Prepare special tools: clutch centering tool, torque wrench, Phillips screwdriver, socket set, and special gaskets for pressure plate fixing bolts.
Clean the splines of the transmission input shaft and the surface of the flywheel to remove oil stains and iron filings. If there are worn grooves on the flywheel, it should be ground or replaced.
2. Pre-treatment of Parts
Apply a small amount of high-temperature grease to the splines of the transmission input shaft (only apply to the splines, and avoid getting it on the friction surface) to prevent jamming after installation.
Inspect the clutch release bearing to ensure it rotates smoothly without abnormal noise. If replacement is needed, install a new bearing synchronously.
II. Specific Installation Steps
1. Positioning of Flywheel and Pressure Plate
Fix the flywheel on the engine cylinder block, and confirm that the flywheel bolts have been tightened to the standard torque (the torque of flywheel bolts for Hyundai models is generally 80–100 N·m; refer to the vehicle maintenance manual for details).
Place the clutch pressure plate with its friction surface facing the flywheel stably on the flywheel positioning pins, ensuring that the pressure plate is fully attached to the flywheel without deviation.
2. Tightening of Pressure Plate Fixing Bolts
3. Centering Installation of Clutch Disc
Fit the dual-clutch disc onto the input shaft splines (note the distinction between the driving and driven disc directions; usually, the side marked "FRONT" faces the pressure plate). Insert a special centering tool into the center hole of the clutch disc to ensure coaxiality among the clutch disc, pressure plate and flywheel — this is a key step to avoid gear shifting difficulties and clutch jitter.
Keep the centering tool fixed until the transmission and engine are fully docked before removal.
4. Transmission Docking and Subsequent Inspection
Lift the transmission and slowly dock it with the engine cylinder block, ensuring that the input shaft is smoothly inserted into the clutch disc splines without jamming.
Install the connecting bolts between the engine and transmission, and tighten them crosswise to the standard torque.
Connect the clutch release fork and the pipeline of the release bearing (for hydraulic DCT, pay attention to bleeding air from the system).
Before starting the vehicle, press the clutch pedal several times to reset the release bearing and diaphragm spring, then test whether gear shifting is smooth without abnormal noise.
Installation Precautions for Dual-Clutch Pressure Plate of Hyundai Vehicles
1. Part Cleaning and Protection
The friction surface of the pressure plate, friction layer of the clutch disc, and end face of the flywheel must be free of oil contamination, iron filings and dust. If contaminated with oil, wipe them thoroughly with clutch-specific cleaning agent. Do NOT use gasoline or diesel for cleaning (as they tend to leave residual impurities). Avoid direct contact with the friction surfaces with hands after cleaning to prevent contamination from hand grease.
Inspect the wear condition of the diaphragm spring fingers of the pressure plate. Replace the pressure plate if grooves or deformation are found on the fingers. If there is a wear step (exceeding 0.2mm) on the flywheel end face, the flywheel shall be ground or replaced.
2. Strict Verification of Installation Direction
Place the pressure plate with its friction surface facing the flywheel. Incorrect installation will cause clutch failure to disengage and the vehicle to be unable to shift gears.
Distinguish between the driving and driven discs of the dual-clutch assembly. The discs are usually marked with words such as FRONT or TO TRANSMISSION. Be sure to install them according to the marked direction. Reverse installation will lead to poor clutch engagement and jitter.
3. Accurate Torque Control
Tighten the pressure plate fixing bolts in batches following a cross-symmetric sequence. Never fully tighten a single bolt at one time, which may cause warping deformation of the pressure plate.
The bolt torque must strictly comply with the maintenance manual of the corresponding vehicle model (the torque of Hyundai DCT pressure plate bolts is mostly 25–35 N·m, and that of flywheel bolts is 80–100 N·m). Excessive torque may lead to bolt elongation and fracture, while insufficient torque will cause abnormal noise during driving and pressure plate loosening.
Recheck the torque of all bolts after tightening to ensure no omissions.
4. Non-substitutability of Special Tools
A clutch centering tool must be used to fix the position of the clutch disc, ensuring coaxiality among the clutch disc, pressure plate and flywheel. Do NOT use screwdrivers, transmission input shafts or other tools as substitutes. Otherwise, it will result in eccentric wear of the clutch disc, gear shifting jams and starting jitter.
Keep the centering tool fixed until the engine and transmission are fully docked and fastened before removal.
5. Supporting Inspection of the Release System
Inspect the release bearing before installation to ensure it rotates smoothly without jamming or abnormal noise. Replace the bearing synchronously if it is loose or stuck. Apply a small amount of high-temperature grease to the guide sleeve of the release bearing to avoid dry friction and abnormal noise.
Ensure the release fork push rod and oil pipe joints of the hydraulic dual-clutch are well-sealed. Bleed air from the hydraulic system in accordance with specifications after installation; otherwise, the clutch pedal will feel spongy and the clutch will fail to disengage completely.
References：
Hyundai Original Factory Workshop Manual
Applicable Models: Mainstream DCT models such as Hyundai Kona (OS, 2018–2025), Tucson (NX4, 2020–2023), and Sonata (LF).
Core Chapters:
DCT (Dual Clutch Transmission) System → Dual Clutch Assembly / Installation. This section includes requirements for torque specifications, special tool models (e.g., SST 09430-2A240), centering installation, friction surface cleaning, release bearing inspection, and hydraulic system bleeding.
Authoritative Basis: Officially issued by the manufacturer, it serves as the highest standard for maintenance operations. Torque values, installation steps, and prohibited practices shall all comply with this manual.
Hyundai Technical Service Bulletin (TSB)
Key Content: Supplementary installation processes for specific batches of DCTs, and handling specifications for common faults (e.g., pressure plate warping, incomplete disengagement), including bolt torque corrections and key points for the use of centering tools.
Access Channels: Hyundai dealer after-sales system, professional maintenance databases (e.g., Alldata, Mitchell).
Industry Universal Maintenance Specifications
Sources:
Automotive Clutch Maintenance Technical Specifications issued by automotive maintenance industry associations (e.g., China Automotive Maintenance and Repair Association), and general guidelines from professional transmission maintenance organizations (e.g., ZF After-sales Service, Aisin After-sales Service).
Core Content: General requirements such as cross-symmetric tightening of pressure plate bolts, strict prohibition of oil contamination on friction surfaces, and non-substitutability of special tools, which are consistent with Hyundai’s original factory specifications.
Third-party Professional Materials
Sources: Maintenance encyclopedias for Hyundai models on platforms such as Autohome and Bitauto, as well as practical operation shares on professional maintenance forums (e.g., Automotive Maintenance Technology Forum).
Notes: The content is mostly simplified based on the original factory manual, suitable for quick reference. However, the original factory manual shall prevail in all cases.
Corresponding Relationship Between Key Clauses and Sources
| Clause Content | Core Source |
|---|
| Cross-symmetric tightening of pressure plate bolts with a torque of 25–35 N·m | Hyundai DCT Workshop Manual (e.g., for Tucson NX4, Kona OS) |
| Use of clutch disc centering tool | Hyundai DCT Workshop Manual (with clear special SST model numbers) |
| Prohibition of oil contamination on friction surfaces and flywheel cleaning | Installation Warning chapter of Hyundai DCT Workshop Manual |
| Inspection and lubrication of release bearing | Clutch Fork and Bearing chapter of Hyundai DCT Workshop Manual |
| Gear shifting test and running-in requirements after installation | Post-Installation Check chapter of Hyundai DCT Workshop Manual |
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