Installation Method for Mitsubishi Clutch Disc (Outer Diameter: 180mm, Tooth Count: 24)

I. Pre-installation Preparation

Tool and Material Preparation

• Specialized Tools: Clutch centering tool (matched with the clutch disc spline), torque wrench, socket set, crowbar, Phillips/flathead screwdriver, flywheel locking tool.

• Materials: Clutch disc meeting specifications (outer diameter 180mm, tooth count 24), clutch pressure plate, release bearing, pilot bearing (if equipped), high-temperature grease, cleaning agent, sandpaper (400 grit).

Component Inspection

• Clutch Disc: Check that the friction lining is free of cracks, oil contamination and burn marks; ensure the spline teeth are not worn or deformed, and the damping springs are securely fastened. Verify that the spline tooth count is 24 and the 180mm outer diameter matches the pressure plate and flywheel.

• Pressure Plate: Inspect the pressure plate surface for flatness, ensuring no grooves or burn marks are present. Confirm that the diaphragm spring has uniform elasticity and the release fingers are not deformed.

• Flywheel: Check the finish of the flywheel friction surface. Minor scratches can be polished with sandpaper; severely worn or warped flywheels must be replaced. Secure the flywheel using a flywheel locking tool and check that the bolt torque complies with OEM standards.

• Release Bearing: Rotate the bearing to ensure smooth operation without abnormal noise. Apply a small amount of high-temperature grease to the outer ring of the bearing.

II. Core Installation Steps

Flywheel and Clutch Disc Positioning

1. Thoroughly clean the flywheel friction surface and pressure plate mounting surface to remove oil stains and iron filings, ensuring the surfaces are dry and free of impurities.

2. Place the clutch disc in the center of the flywheel. It is imperative to pass a centering tool through the clutch disc spline and insert it into the pilot bearing bore of the transmission input shaft, ensuring complete concentricity between the clutch disc and the flywheel (this is a critical step to prevent clutch judder and gear shifting difficulty).

3. Confirm the clutch disc orientation: The side of the friction lining with damping springs or marked identification should face the pressure plate. (Some Mitsubishi clutch discs are marked with "FLYWHEEL SIDE", which must face the flywheel.)

Pressure Plate Fixation and Torque Control

1. Place the clutch pressure plate over the clutch disc and align the mounting bolt holes of the pressure plate with those of the flywheel.

2. Install the pressure plate fixing bolts using the cross-diagonal tightening method, and tighten them in three stages to the torque specified by the OEM (for most Mitsubishi models, the pressure plate bolt torque ranges from 18–22N·m; refer to the OEM service manual of the specific model for exact values).

3. Maintain the position of the centering tool during the tightening process to prevent clutch disc displacement. Only after all bolts are fully tightened should the centering tool be slowly withdrawn.

Release Mechanism Assembly

1. Mount the release bearing onto the clutch release fork, and apply a small amount of high-temperature grease to the outer ring of the bearing (do not over-apply grease to avoid it splashing onto the friction lining).

2. Install the transmission assembly, ensuring the input shaft is smoothly inserted into the clutch disc spline without jamming. Connect the release fork to the clutch cable/hydraulic pushrod, and adjust the release clearance to meet OEM standards.

III. Post-installation Precautions

Assembly Recheck

• Inspect the clutch pedal free travel to ensure it complies with the vehicle's technical requirements (typically 15–30mm for Mitsubishi models).

• Before starting the engine, depress the clutch pedal repeatedly 5–10 times to ensure full contact between the release bearing and the pressure plate release fingers.

Running-in Requirements

• A cold running-in period is required after installation: Within the initial 500km of vehicle operation, avoid driving in half-clutch mode, rapid acceleration and heavy loading. Fully depress the clutch pedal for each gear shift to minimize wear on the friction lining.

Troubleshooting

• If clutch judder, gear shifting difficulty or incomplete release occurs, inspect the following: whether the clutch disc is improperly centered; whether the pressure plate bolt torque is evenly applied; whether the release bearing is jammed; and whether the flywheel surface is warped.

IV. Key Technical Basis

1. This installation process complies with the clutch system assembly specifications outlined in the Mitsubishi Service Manual.

2. The clutch disc with an outer diameter of 180mm and 24 spline teeth is suitable for certain Mitsubishi compact models (e.g., Mirage, Colt, etc.). For precise vehicle model compatibility, refer to the OEM parts catalog queried via the vehicle's VIN.

Precautions for Installing Mitsubishi Clutch Disc (Outer Diameter: 180mm, Tooth Count: 24)

I. Key Pre-installation Precautions

Parts Matching Verification

1. In addition to confirming that the clutch disc has an outer diameter of 180mm and 24 spline teeth, it is necessary to simultaneously check that the friction lining thickness and spline tooth width are consistent with the OEM parameters, so as to avoid poor clutch engagement caused by part dimensional deviations.

2. Check the marked orientation of the clutch disc. Some clutch discs for Mitsubishi models are labeled with "FLYWHEEL SIDE" (facing the flywheel) or "TRANSMISSION SIDE" (facing the transmission). Reversed installation will directly lead to incomplete clutch release and gear shifting failure.

Cleaning and Protection Requirements

1. The friction surfaces of the flywheel, pressure plate and clutch disc must be thoroughly degreased with a special cleaning agent, and must not be contaminated with engine oil or grease, otherwise it will cause clutch slipping and judder.

2. During the disassembly and installation process, avoid directly touching the working surface of the friction lining with hands to prevent sweat and oil stains from adhering; if contaminated accidentally, re-clean it with a cleaning agent.

Tool Standardization

1. A special centering tool matched with the spline of the clutch disc must be used. It is forbidden to use the transmission input shaft as a substitute for the centering tool, otherwise the coaxiality between the clutch disc and the flywheel cannot be guaranteed, leading to gear shifting noise in the later stage.

2. A torque wrench must be used to tighten the pressure plate bolts. It is strictly prohibited to use an air impact wrench for violent tightening, so as to prevent bolt stretching deformation or flywheel and pressure plate distortion.

II. Core Precautions During Installation

Pressure Plate Bolt Tightening Specifications

1. Strictly implement the cross-diagonal step-by-step tightening method: tighten the bolts in three stages, first to 50% of the specified torque, then to 80%, and finally to the torque specified by the OEM (for most Mitsubishi models, the torque ranges from 18–22N·m; refer to the service manual of the specific model for exact values).

2. Maintain the fixed position of the centering tool during the tightening process. If the centering tool is found to be loose or displaced, reposition the clutch disc before continuing to tighten.

Lubrication Taboos for the Release Mechanism

Transmission Assembly Taboos

1. When lifting and installing the transmission, align the input shaft with the clutch disc spline slowly. Forcible prying of the transmission is prohibited to prevent spline tooth deformation or clutch disc displacement.

2. After the transmission is installed in place, check the travel of the release fork to ensure that the contact clearance between the release fork and the release bearing meets the OEM standards (generally 2–5mm).

3. References：