Clutch plate 5010452572，81303010375，5010244077，806474 81303010461，5010244242 81303010664， 807589，806218 807591，AR00123，060144，300161 for Man

I. MAN Clutch Friction Disc Installation Steps

• Inspect the Pilot Bearing: This is the most easily overlooked component on MAN trucks. After removing the gearbox, check the pilot bearing located in the center of the flywheel.

• Action: Rotate the bearing by hand; it must turn smoothly without resistance. If the bearing is worn or seized, it must be replaced. MAN input shafts are long; a seized bearing will directly cause rapid wear of the new friction disc splines or shudder during takeoff.

• Clean the Friction Disc: New friction discs are usually coated with anti-rust oil. They must be thoroughly cleaned and dried using a solvent. Any residual oil will cause clutch slippage.

• Observe Markings: Check the side of the friction disc, which is usually stamped with "Flywheel Side" or "Gearbox Side."

• General Rule: If unmarked, the side with the longer or more prominent damping springs usually faces the gearbox, while the shorter side faces the flywheel.

• Note: Some MAN models (such as the older F2000 or newer TGX) may use symmetrical friction discs. However, to be safe, always verify against the installation diagram corresponding to the part number.

• Apply a small amount of high-temperature grease (preferably Molybdenum Disulfide-based, such as Molykote or the OEM-specified grease) to the inside of the friction disc hub and the gearbox input shaft splines.

• Warning: Grease must only be applied to the splines; under no circumstances should it contact the friction surfaces.

• Install the Friction Disc: Place the friction disc onto the flywheel in the correct orientation.

• Insert Alignment Tool: Insert a dedicated alignment tool (or an old input shaft) into the friction disc spline hole and through the pilot bearing in the flywheel center.

• Adjust Position: Move the friction disc up and down, left and right, ensuring the alignment tool rotates easily and smoothly through the pilot bearing and splines without sticking. This is the most critical step in MAN truck installation because the tolerance between the MAN gearbox input shaft and the pilot bearing is very tight.

• Place the pressure plate (clutch cover) over the disc, ensuring the locating dowels align with the holes in the flywheel.

• Tighten Bolts in Diagonal Sequence: Tighten the pressure plate bolts in a diagonal sequence, performing this in 3-4 stages.

• Torque Standard: MAN pressure plate bolts typically require high torque (e.g., M12 bolts may require 90-110Nm, depending on the specific model). A torque wrench must be used.

• Remove Tool: Once the bolts are fully tightened, remove the alignment tool.

• MAN typically uses a release bearing with a guide sleeve.

• Check the release bearing guide sleeve for wear.

• Apply Grease: Apply grease to the contact area between the release bearing and the guide sleeve.

• Install the bearing, ensuring the return spring is hooked correctly.

II. MAN-Specific Precautions

• Some high-horsepower MAN tractors (e.g., those with hydraulic retarders) use twin-disc clutches.

• Installation Order: Flywheel -> 1st Friction Disc -> Intermediate Plate -> 2nd Friction Disc -> Main Pressure Plate.

• Note: The direction of both friction discs must be correct, and the drive pins on the intermediate plate must be intact.

• MAN has high requirements for flywheel surface flatness. Before installation, use a dial indicator to check flywheel face runout.

• If runout exceeds 0.2mm, it is recommended to have the flywheel resurfaced or replaced; otherwise, the new friction disc will cause severe shudder during takeoff.

• Due to the length and weight of the MAN gearbox input shaft, even slight misalignment will cause the shaft to jam against the friction disc splines during gearbox installation.

• Recommendation: Use a dedicated alignment tool with roller bearings, or use an old input shaft directly for centering to ensure safety.

• If equipped with a Concentric Slave Cylinder (CSC), air must be completely bled from the clutch slave cylinder after installation. The bleed screw on MAN trucks is usually located on the top or side of the gearbox housing; this operation requires two people.

• After installation, try to avoid high-rev starts with the clutch slipping for the first 500 kilometers. Allow the friction disc to fully bed in with the flywheel and pressure plate to extend service life.

1. Mandatory Check: Pilot Bearing

• The Situation: MAN gearbox input shafts are long, and some models are equipped with retarders, making the input shaft heavy and requiring extremely high concentricity.

• Action: Every time the clutch is replaced, the pilot bearing in the center of the flywheel must be inspected or directly replaced.

• Consequences: If the bearing is seized, worn, or dry, the gearbox input shaft will wobble (run eccentric) during rotation. This leads to:

• Rapid wear and ovalization of the new friction disc splines.

• Severe shudder/vibration during takeoff.

• Abnormal noise from the gearbox.

2. Core Challenge: Absolute Centering

• Action:

• A dedicated centering tool must be used.

• After placing the friction disc, rotate the centering tool by hand; it must feel silky smooth with no binding or eccentricity.

• Continuously rotate the centering tool while tightening the pressure plate bolts to prevent the tool from jamming due to pressure plate deformation.

• Taboo: When installing the gearbox, if the input shaft cannot be pushed in, never use a crowbar or jack to force it. This will directly break the pressure plate diaphragm spring or damage the friction disc splines.

3. Lubrication Boundaries: Splines vs. Surfaces

• Where to Apply Oil (Small amount):

• Inside the friction disc hub: Apply high-temperature grease (Molybdenum Disulfide).

• Gearbox input shaft splines: Apply high-temperature grease.

• Release bearing guide tube: Apply dedicated grease.

• Where Oil is Strictly Forbidden:

• Friction disc facing (lining): Not a single drop is allowed.

• Flywheel surface.

• Pressure plate surface.

• Note: New friction discs come with anti-rust oil from the factory. They must be thoroughly cleaned with solvent and dried before installation; otherwise, slippage is guaranteed.

Details of Content Sources

• Pilot Bearing Replacement Requirements & Release Stroke Standards: Based on data from MAN Truck & Bus OEM Service Manuals (available within the MAN ServicePort system).

• Pressure Plate Bolt Torque Parameters & Twin-Disc Installation Sequence: Referenced from specific OEM maintenance documentation for MAN models (such as the TGX, TGS, etc.).

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