Pre-Installation Preparation

1. Park the vehicle in a safe area, engage the handbrake firmly, lift and secure the vehicle with a hoist. Remove relevant connecting components between the engine and transmission to expose the clutch assembly. During disassembly, use special tools to fix the flywheel and mark alignment positions for components.

2. Verify that the new clutch disc model is compatible. Slide the new clutch disc onto the transmission input shaft to test for smooth spline engagement. Meanwhile, clean the surfaces of the flywheel and pressure plate; thoroughly remove any oil contamination to prevent subsequent clutch slippage.

3. Prepare Mitsubishi genuine grease (Part No. 0101011 or equivalent). Apply a small amount of grease only to the splined hub of the clutch driven disc. Note: Do not add additional lubricating oil to the release bearing or transmission pilot bearing.

Core Installation Operations

1. Clutch Disc Positioning: Ensure the torsion damper side of the clutch driven disc faces the pressure plate. Insert a special centering tool or the transmission input shaft into the central splined hub and transmission pilot bearing to center the clutch disc, preventing displacement and ensuring alignment with the transmission shaft pilot bearing.

2. Install Clutch Cover and Pressure Plate: Align the alignment marks on the clutch cover, pressure plate, and diaphragm spring. Simultaneously, align the clutch cover with the locating pins on the flywheel to avoid misalignment that may affect transmission precision.

3. Tighten Bolts: Gradually tighten the mounting bolts in a diagonal sequence to a torque specification of 25Nm. Do not fully tighten bolts on one side at a time, as uneven pressure on the pressure plate can cause abnormal clutch disc wear.

Subsequent Assembly and Commissioning

1. Install the release bearing: Push the pressure spring into the release bearing, pre-compress the retaining ring to dimension A=18mm, then lock it in place with a torque of 15Nm. Apply grease to the contact points of the release fork and push rod to ensure smooth release operation.

2. Adjust the position of the clutch release fork shaft lever so that the distance to the fixed cable nut bracket is 195mm - 205mm. Subsequently, adjust the clutch pedal free travel to 15mm - 25mm to ensure proper clutch engagement and disengagement.

3. Install auxiliary components such as the rubber dust cover. Inspect the engine rear main bearing oil seal and transmission front oil seal for leaks; repair any leaks before completing final assembly.

Post-Installation Inspection

1. Before starting the vehicle, manually actuate the release fork to check for smooth clutch engagement and return without jamming.

2. After starting the vehicle, test clutch engagement through gear shifting. Confirm there are no issues such as slippage, vibration, or abnormal noise. If abnormalities occur, recheck bolt tightness and component installation positions.

Key Precautions for Mitsubishi Clutch Disc Installation

I. Safety Operation Specifications

Vehicle Securing and Protection

1. Use a qualified hoist to fix the vehicle, aligning support points with the designated frame positions. Never perform operations with only a jack for support. Firmly engage the handbrake and shift into low gear to prevent vehicle movement.

2. Disconnect the negative battery terminal before operation to avoid electrical system short circuits. Wear gloves and safety goggles to protect against oil splashes and component scratches.

Tool Usage Requirements

1. Use a torque wrench for bolt tightening, strictly following Mitsubishi’s original specifications: 25Nm for pressure plate bolts and 15Nm for release bearing bolts. Never tighten by feel, as this may cause pressure plate deformation or bolt loosening.

2. Prioritize using Mitsubishi’s special centering tool (e.g., MD998767) for clutch disc positioning. If no special tool is available, a transmission input shaft of the same model can be used as a substitute, but avoid scratching the splined hub with the shaft end.

II. Critical Taboos for Component Installation

Prohibition of Reversing Clutch Disc Direction

1. Ensure the torsion damper side of the driven disc (the end with the spring damping structure) faces the pressure plate. Reversing the direction will result in incomplete clutch disengagement, difficult gear shifting, or even damage to the damper springs.

2. Never apply grease or engine oil to the friction surface of the clutch disc, flywheel, or pressure plate. Only a small amount of Mitsubishi genuine grease (Part No. 0101011) is allowed on the driven disc’s splined hub. Excessive lubrication will cause clutch slippage and failure.

Alignment of Pressure Plate and Flywheel

1. Mark alignment positions between the flywheel, pressure plate, and clutch cover during disassembly, and strictly align them during installation. If marks are lost, ensure the pressure plate’s locating pins fully fit into the flywheel’s pin holes. Misalignment will cause uneven pressure plate loading and abnormal clutch disc wear.

2. Do not forcibly strike the pressure plate or flywheel. If locating pins are stuck, apply a small amount of rust remover (e.g., WD-40) for lubrication before tapping gently to avoid damaging pin holes or pins.

III. Assembly Precision and Clearance Control

Adjustment of Free Travel and Release Clearance

1. The clutch pedal free travel must be controlled between 15mm–25mm, and the distance from the release fork shaft lever to the fixed bracket must be 195mm–205mm. Deviations from this range will cause incomplete disengagement (excessively small travel) or slipping engagement (excessively large travel).

2. After installation, manually press the pedal 3–5 times and recheck if the free travel remains stable. If travel changes occur, inspect for wear on the release fork shaft bushing or cable jamming.

Seal and Lubrication Management

1. Before installation, inspect the engine’s rear main bearing oil seal and the transmission’s front oil seal for aging or leakage. If oil contaminates the flywheel or clutch disc, replace the seals and thoroughly clean the components; otherwise, clutch slippage will occur.

2. Apply only a small amount of high-temperature grease (e.g., Mitsubishi 0101012) to the contact points of the release bearing and release fork. Never use ordinary grease, as it will fail at high temperatures, causing jamming and abnormal noise.

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References：

Source Verification of Mitsubishi Clutch Disc Installation Precautions

1. Core Parameters Align with Mitsubishi’s General Maintenance Standards

2. Installation Logic Matches Core Principles of Mitsubishi’s Clutch Service Manuals

• Original Force Documents emphasize that excessive grease during clutch installation can cause slippage;

• Autohome’s maintenance content highlights critical installation inspection indicators, including diaphragm spring height deviation and clutch friction disc rivet sinkage.

3. Complete Versions of the Referenced Manuals Are Currently Unretrievable