Integrated Installation Method for Hyundai & Kia Clutch Pressure Plate + Friction Disc (Driven Disc)

I. Core Pre-installation Preparations (Mandatory Items)

1. Electrical and Mechanical Safety Isolation

• Turn off the ignition switch, remove the key, disconnect and securely fasten the negative cable of the 12V battery to prevent damage to electronic control components caused by accidental activation of the starting circuit.

• Lift the vehicle with a two-post lift, or use a jack paired with safety stands for dual support. Place an additional jack under the transmission to prevent it from falling after separation from the engine.

• Drain all transmission gear oil completely, remove the drive shafts, starter motor and flywheel housing guard plate, detach the transmission-engine connecting bolts, and separate the entire transmission assembly.

2. Tool and Consumable List (Precision Priority)

3. Component Cleaning and Condition Inspection

• Flywheel Cleaning and Inspection: Use sandpaper to remove oil stains, rust and burn marks from the flywheel end face, then wipe and dry with anhydrous ethanol. Measure the flywheel end face runout with a dial indicator; if runout exceeds 0.2mm, the flywheel must be resurfaced or replaced, otherwise it will cause clutch engagement shudder.

• Pilot Bearing Inspection: Rotate the crankshaft pilot bearing; it should turn smoothly without jamming or excessive clearance noise. Replace it immediately if worn beyond the limit to avoid eccentric wear of the friction disc.

• Friction Disc Orientation Confirmation (Critical Error Prevention Point)

• For 1.6L/1.7L high-pressure diesel models: The side of the friction disc marked "T/M SIDE" must face the transmission;

• For 2.0L/1.7L low-pressure diesel models: The side of the friction disc marked "FLYWHEEL SIDE" must face the flywheel;

• For unmarked models: The side with protruding damping springs faces the transmission. Reversed installation will lead to incomplete disengagement and failure to shift gears.

• Component Pre-lubrication: Apply a thin coat of high-temperature grease to the following parts (excessive grease is strictly prohibited, as it will splash onto the friction surface and cause slipping):

• Transmission input shaft splines;

• Release bearing guide surface and release fork fulcrums;

• Friction disc spline hub (apply a small amount, avoiding contact with the friction surface).

II. Integrated Installation Steps (Synchronized Assembly of Pressure Plate + Friction Disc)

Step 1: Friction Disc Centering and Positioning (Core Process)

1. Wipe the flywheel end face clean again to ensure no impurities or burrs remain.

2. Place the friction disc (driven disc) in the center of the flywheel, aligning the spline hub with the crankshaft pilot bearing.

3. Insert the OEM centering tool (or use the transmission input shaft as a substitute) through the friction disc spline hub and pilot bearing to ensure full coaxiality between the friction disc and flywheel. Rotate the friction disc slightly to verify there is no jamming.

Step 2: Pressure Plate Assembly and Torque Tightening

1. Align the clutch pressure plate with the assembly marks on the flywheel (align evenly if there are no marks), cover it over the friction disc, and ensure the pressure plate's diaphragm spring is directly facing the friction disc.

2. Uniformly pre-tighten all pressure plate fixing bolts: Tighten each bolt 1-2 turns to ensure the pressure plate fits flat against the flywheel without deflection.

3. Tighten the bolts in 2-3 stages following the diagonal cross sequence (full tightening in a single step is strictly prohibited). Torque values vary by model:

4. After tightening, slowly pull out the centering tool and recheck whether the friction disc has shifted.

Step 3: Release Mechanism Assembly

1. Install the new release bearing onto the transmission input shaft guide sleeve, ensuring it rotates smoothly.

2. Install the release fork, engage the return spring, lubricate the connection fulcrum between the release fork and transmission case, and ensure the release fork swings freely without jamming.

3. Adjust the position of the release fork to maintain a 1.0±0.2mm gap between the release bearing and diaphragm spring (measured with a feeler gauge). Excessively small gaps can cause clutch slippage during semi-engagement, while excessively large gaps will lead to incomplete disengagement.

Step 4: Transmission Reset and System Calibration

1. Lift the transmission, align it with the engine block mating surface, and slowly push the transmission into place (rotate the input shaft slightly during the process to facilitate spline engagement with the friction disc spline hub). Avoid violent impact to prevent damage to the splines.

2. Tighten the transmission-engine connecting bolts (45-60 N·m) and transmission bracket bolts to OEM torque specifications (refer to the vehicle-specific service manual for exact values).

3. Hydraulic Clutch System Bleeding: Open the slave cylinder bleed screw, repeatedly depress and release the clutch pedal until no air bubbles are present in the discharged fluid, and the pedal stroke meets the standard (145±3mm for 1.6L models; 150±3mm for 2.0L models).

4. Electronic Clutch Matching (Exclusive to DCT Dual-Clutch Models): Use the OEM GDS diagnostic tool to perform the "Clutch Actuator Learning" function, calibrate the engagement point and pedal stroke, and clear fault codes.

III. Post-installation Verification and Commissioning

1. Static Mechanical Inspection

• Manually rotate the transmission input shaft; it should turn smoothly without jamming or significant wobbling, indicating no interference between the friction disc and pressure plate.

• Push the release fork gently; the release bearing should lift the diaphragm spring evenly and return quickly when released.

2. Dynamic Road Test Verification

• Start the engine, repeatedly depress and release the clutch pedal at idle speed; the pedal resistance should be consistent with no abnormal noise.

• Shift sequentially through gears 1 to 5; gear changes should be smooth without jolting, difficult shifting or incomplete disengagement.

• Low-speed start test: The clutch engagement point should be clear with no slippage or shudder. No power loss should occur during full-load climbing.

3. Hot Vehicle Re-inspection

• After driving the vehicle for 10-20 km, stop and check the temperature of the clutch housing; the normal operating temperature should be ≤80℃ with no local overheating.

• Recheck the torque of the pressure plate bolts to confirm there is no loosening.

References：

I. Core Authoritative Sources (Original Factory Technical Materials)

1. Hyundai & Kia Original Factory Service Manual (WSM)

• Applicable Chapters: Corresponding to the Clutch System chapter (e.g., CH-01/03) in the service manuals for mainstream MT models (1.6L/2.0L gasoline, 1.7L diesel). It covers core parameters including the centering tool model (09411-1P000), pressure plate bolt torque (14.7–21.6 N·m for 1.6L models, 11.8–14.7 N·m for 2.0L/1.7L diesel models), release clearance (1.0±0.2 mm), driven disc orientation markings, and lubrication specifications.

• Retrieval Path: Input the vehicle’s VIN in the Hyundai & Kia GDS/TIS system to query the model-specific service manual, or obtain the PDF file of the Clutch System chapter corresponding to the vehicle’s year and displacement via authorized dealer maintenance terminals.

2. Hyundai & Kia Technical Service Bulletin (TSB)

• Supplementary Basis: For example, the Kia TSB SC-xxx series, which clearly specifies operational requirements such as driven disc orientation error prevention, electronic clutch actuator learning, and hydraulic system bleeding temperature (0–40℃), to avoid faults like incomplete disengagement and gear-shifting shock.

• Retrieval Path: Navigate to the TSB section on the GDS/TIS platform, filter by vehicle model/year/system, and obtain the complete bulletin documents.

II. Industry Universal Technical Standards