Installation Method for Clutch Pressure Plates of Howo, FAW and Dongfeng

I. Pre-installation Preparation

Tool and Accessory Preparation

Cleaning and Inspection

1. Clean the flywheel end face and pressure plate friction surface to remove oil stains, rust and metal debris, ensuring no deformation or cracks.

2. Check that the driven disc spline, damping spring and friction plate are intact; the release bearing rotates smoothly without jamming.

3. Verify that the pressure plate model matches the vehicle VIN, and confirm that the positioning pins and bolt holes are consistent with those of the flywheel.

II. Removal of Old Pressure Plate (Reverse Installation Procedure)

1. Separate the Gearbox: Support the gearbox, remove the connecting bolts with the engine, move the gearbox backward, and take off the old pressure plate assembly.

2. Remove the Mounting Bolts: Loosen the pressure plate mounting bolts (usually 6 pieces) gradually in a diagonal sequence, and take off the old pressure plate and driven disc.

3. Inspect Components: Check the flywheel ring gear, crankshaft rear oil seal and pilot bearing, and replace them if necessary.

III. Installation Steps for New Pressure Plate

Positioning and Centering

1. Install the centering mandrel, sleeve the driven disc onto the mandrel, and ensure that the damper disc faces the pressure plate.

2. Align the pressure plate with the flywheel positioning pins, fit the spigot surface, manually screw in 3 diagonal bolts (do not fully tighten) to reserve adjustment allowance.

Connection and Torque Control

Key Operations

1. Apply a small amount of lubricating grease to the driven disc spline and input shaft, and wipe off excess grease to prevent slipping.

2. Install the release bearing to ensure uniform contact with the diaphragm spring, and the free clearance meets the specification (usually 3-5mm).

3. Reinstall the gearbox to ensure smooth matching between the input shaft and the driven disc spline without jamming.

IV. Brand-specific Adaptation Points

V. Post-installation Test and Verification

1. Reset and Power-on: Reconnect the negative battery terminal, and check that the wiring connections are firm and well-insulated.

2. Pedal Travel: Adjust the clutch pedal free travel (usually 15-25mm) to ensure thorough disengagement and smooth engagement.

3. No-load Test: Start the engine, check that the disengagement/engagement is smooth without abnormal noise or jitter.

4. Road Test: After driving 50-100km, recheck the torque of pressure plate bolts to confirm no loosening.

VI. Safety and Technical Specifications

1. Wear clean gloves throughout the process to avoid oil contamination of friction surfaces and prevent slipping.

2. Bolts must be tightened gradually in a diagonal sequence; avoid forced one-sided tightening to prevent pressure plate deformation and dynamic balance failure.

3. Apply special lubricating grease to the contact area between the release bearing and diaphragm spring to avoid dry friction.

4. After installation, check that the clutch disengagement point is clear, gear shifting is smooth without jamming, and there is no abnormal heating.

VII. Authoritative Information Sources

• Howo: Sinotruk Original Factory Service Manual, Clutch Assembly Installation Specifications

• FAW: FAW Jiefang/Bestune Original Factory Service Manual, Clutch Assembly Technical Standards

• Dongfeng: Commercial Vehicle Service Manual, General Clutch Installation Procedures

• Industry Standard: QC/T 25-2014 Technical Conditions of Automobile Dry Friction Clutch Assembly

Precautions for Installing Clutch Pressure Plates of Howo, FAW and Dongfeng

I. Safety Operation Specifications

1. Wear clean, oil-free protective gloves throughout the installation process. Never touch the friction surface of the pressure plate or the friction disc of the driven plate directly with hands, to prevent clutch slippage and failure caused by grease on hands. Do not perform any operations without disconnecting the negative battery terminal, so as to avoid short circuits that may burn electrical components.

2. When removing and lifting the gearbox, use a dedicated support frame to hold it steadily. Never lift the gearbox by hand to prevent it from slipping and causing personal injury. Keep the gearbox horizontal when moving it, and avoid colliding with precision components such as the input shaft and release fork.

3. Keep the installation area clean and dry, free of oil stains, metal debris and dust. Prevent impurities from entering the mating surface between the pressure plate and flywheel, which would cause abnormal wear and jitter of the clutch.

4. Do not directly strike the pressure plate or flywheel end face with hard tools such as iron hammers, to avoid component deformation that affects dynamic balance. If necessary, use a copper hammer or rubber hammer to tap lightly for alignment.

II. Accessory Compatibility Verification Requirements

1. Before installation, verify that the models of the pressure plate assembly and driven plate match the vehicle VIN code. Confirm that the number of pressure plate bolt holes, position of locating pins and spline specifications of the driven plate are consistent with those of the flywheel and input shaft. Most Howo models adopt push-type clutches, while some Dongfeng models use pull-type structures. Mixing different types of clutch components is strictly prohibited.

2. Check that the heights of the diaphragm springs of the new pressure plate are consistent with an error ≤ 0.2mm. Ensure that the friction disc of the driven plate has no cracks or chunking, the damping springs have no looseness, the release bearing rotates smoothly without jamming, and its axial clearance complies with the original factory specifications.

3. Verify that all bolts are of original high-strength specifications, with complete matching lock washers and locating pins. Never replace 

I. Core Information Sources and Reference Content