clutch pressure plate 5010244310，SCPW45，160463，5000249083 5000788573，5000789976，135023710 5000789975，5000826314，83-04560-SX for DAFF 1993-1998, MAN 1995-, Nissan, Renault Trucks

I. General Installation Steps (Applicable to all trucks)

• Cleaning: Clutch driven discs and pressure plates are usually coated with anti-rust oil at the factory. This must be thoroughly cleaned (using a suitable solvent or gasoline) to prevent clutch slippage.

• Inspection: Check the flywheel surface for signs of burning, cracks, or deep grooves. If damage is found, the flywheel must be resurfaced or replaced.

• Insert a centering tool (clutch aligner) into the splined hub of the clutch disc.

• Place the clutch disc onto the flywheel and use the centering tool to ensure it is perfectly concentric with the flywheel. Failure to center correctly will prevent the transmission input shaft from engaging during installation or cause shudder during acceleration.

• Place the pressure plate over the clutch disc, ensuring the locating dowels (or holes) on the pressure plate align with the corresponding positions on the flywheel.

• Tighten in a Diagonal Sequence: Tighten the pressure plate retaining bolts in a crisscross (diagonal) pattern.

• Note: Do not fully tighten the bolts in a single pass. Gradually increase torque in 3-4 stages to ensure even clamping force and prevent distortion of the pressure plate.

• Apply a small amount of high-temperature grease (typically Molybdenum Disulfide Lithium-based grease) to the clutch disc splines, the transmission input shaft splines, and the release bearing guide sleeve.

• Warning: Do not over-apply grease. Under no circumstances should grease come into contact with the friction surfaces of the disc.

• Check that the release bearing rotates freely and smoothly.

• Install the release bearing and its carrier/lever, ensuring the return spring is correctly positioned.

I. Core Principle: Cleanliness and Oil Prevention (Universal for all brands)

• The clutch friction disc (lining) and flywheel surface must be absolutely dry and free of oil.

• Note: During installation, sweat or fingerprints can also cause initial slippage; wearing clean cotton gloves is recommended. If oil is accidentally applied, the part must be thoroughly cleaned with carburetor cleaner and dried.

• New pressure plates may have anti-rust oil on the surface, which must be wiped clean before installation. Failure to do so can result in gas vaporization when heated, potentially causing slippage.

II. Orientation and Centering (The Easiest Step to Get Wrong)

• Nissan / UD: The splined hub of the clutch disc is asymmetrical in many models. The side marked "Flywheel Side" must face the flywheel. If installed backward, the clutch will fail to disengage, and the transmission input shaft bearing will be damaged.

• DAF / Renault: In models with dual-mass flywheels or twin-plate clutches, the order of the intermediate plate and main pressure plate must not be mixed. Installation must strictly follow the disassembly order or the service manual.

• A dedicated centering tool must be used.

• Note: When installing the transmission, if the input shaft feels difficult to push in, never use a crowbar or jack to force it. This will crush the diaphragm spring fingers or damage the transmission bearing. Instead, remove the transmission and recheck the centering.

III. Bolt Tightening Procedure (Determines Flatness)

• This is an iron rule. Tightening must be done in 3-4 stages.

• MAN / DAF: Heavy-duty trucks use large-diameter pressure plate bolts (e.g., M12 or M14). Tightening them in a single pass will deform the pressure plate, causing shudder during takeoff or premature fracture.

• Renault: Some newer Renault trucks require the "Angle Tightening Method" (e.g., tighten to 50Nm, then rotate an additional 90 degrees).

• MAN: Flywheel bolts and pressure plate bolts on MAN trucks typically require very high torque; a calibrated torque wrench is mandatory.

• Check if bolts have pre-applied thread-locking compound. If reusing old bolts, it is recommended to apply thread-locking fluid (such as Loctite 243) to prevent loosening due to long-term vibration, which could damage the engine oil pan.

IV. Lubrication Points (Wrong Location = Disaster)

• Transmission Input Shaft Splines: Apply a small amount of high-temperature grease.

• Release Bearing Guide Sleeve: Apply Molybdenum Disulfide Lithium-based grease.

• Release Fork Pivot Shaft: Apply grease.

• Diaphragm Spring Fingers: This is where the release bearing makes contact.

• Old DAF/MAN models: While older practices suggested using graphite, modern heavy-duty clutches (especially those with ceramic linings) strictly prohibit any grease here. Lubrication will cause uneven force distribution on the fingers, leading to shudder or abnormal noise.

• Friction Surfaces: Not a single drop of oil is allowed.

V. Brand-Specific "Pitfalls" and Sensors

• DAF trucks are often equipped with K0/K1/K2 clutches (with retarders). Installation requires attention to the release bearing travel. If it is a pneumatic-hydraulic system, the pushrod length must be adjusted after installation to ensure proper free play; otherwise, the release bearing will overheat ("burn out").

• The pilot bearing in the center of the MAN flywheel is easily overlooked. If this bearing seizes or wears out, the transmission input shaft will wobble during operation, causing rapid wear of the clutch disc splines. It is recommended to replace this bearing every time the clutch is changed.

• Many Nissan UD models use a central hydraulic release bearing (CSC).

• Note: The hydraulic line connector must be protected during installation; bending is strictly prohibited. Use a special tool to press it into place—do not hammer it. Air must be completely bled from the hydraulic system after installation; otherwise, the clutch will not disengage.

• Newer Renault models (e.g., T-Series) are equipped with an electronic clutch wear adjustment system.

• Note: Do not manually force the adjustment of the pushrod. Connect a diagnostic computer (such as Premium Tech Tool) and execute the "Clutch Centering/Calibration" procedure to allow the ECU to automatically learn the clearance. Manual adjustment may trigger fault codes.

References：

Explanation of Content Sources

• DAF: References the self-adjustment mechanism and twin-plate clutch installation specifications found in the K-Series clutch service manuals.

• MAN: Based on the pilot bearing replacement requirements and release stroke standards outlined in the MAN Truck & Bus OEM manuals.

• Nissan / UD: Incorporates details regarding directional markings on clutch discs and the installation/bleeding process for Concentric Slave Cylinders (CSC) from Nissan UD heavy-duty vehicle repair data.

• Renault Trucks: References the electronic clearance adjustment system calibration and auxiliary spring installation positions found in the service manuals for the Renault T/C Series.

Accessing Official Resources

1. DAF: DAF Technical Information Portal (Account required).

2. MAN: MAN ServicePort (OEM repair system).

3. Nissan / UD: Nissan Commercial Vehicle Service Manual (includes UD series).

4. Renault Trucks: Renault Trucks Premium Tech Tool (Diagnostic and repair manual platform).