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Type :
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clutch release bearing
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Specification :
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Pulley :
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Brand :
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NUOJIN
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Number :
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41420-2B000，J2400310
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Quality :
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new
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Delivery time :
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30 days
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This installation procedure is fully compatible with the clutch system structure of Hyundai and Kia models. Below is a general installation method compiled in accordance with the maintenance specifications for common models such as the Cerato. The specific steps are as follows:
Prepare tools and accessories, including a jack, wrenches, snap ring pliers, and Kia - specific clutch installation tool (e.g., 09411-25000). Also, have a new clutch release bearing and multi - purpose grease (e.g., CASMOLY L9508) ready.
Park the vehicle on a level surface, disconnect the power supply, lift the vehicle with a jack, and secure it firmly with supports to prevent the vehicle from shaking during operation. In addition, inspect the new clutch release bearing to ensure there is no damage and it rotates smoothly.
First, remove the bolts connecting the transmission assembly to the engine, and take off the entire transmission assembly. At this point, you can see the connection parts of the clutch cover assembly, the clutch release bearing, and the release fork.
If the clutch cover is attached to the flywheel, insert snap ring pliers under the wave washer, press the clutch release bearing down against the center of the snap ring, expand the snap ring, and then pull out the old clutch release bearing. Next, gradually loosen the bolts connecting the clutch cover to the flywheel in a star - shaped pattern, remove the clutch cover and clutch disc, and place them properly.
Wipe the flywheel surface, transmission input shaft, and the contact parts of the release fork with a clean rag to remove oil stains, iron filings, and other impurities, so as to avoid these impurities affecting the installation accuracy and the operation of components.
Apply an appropriate amount of the prepared grease to the spline part of the clutch disc. Be careful not to use an excessive amount, as this may lead to slipping or vibration of the clutch disc later on.
First, apply grease to the bearing bushing and the contact points between the bearing bushing and the release fork. Then, align the clutch release bearing with the mating position of the release fork and install the clutch release bearing onto the housing bushing.
Install the release lever onto the release fork, ensuring a secure connection and that the clutch release bearing can move flexibly without jamming when the fork swings.
Use a special installation tool to position the clutch disc assembly onto the flywheel. Then, reinstall the clutch cover assembly onto the flywheel. First, temporarily tighten the bolts one or two turns in a star - shaped pattern, and then fasten them to the torque specified for the model. For example, the torque for the clutch cover bolts of 1.6L models is usually 15-22 N·m, and that for D2.0 models is 20-27 N·m.
Align the transmission assembly with the connection position of the engine and install it back. Tighten the fixing bolts to ensure the transmission and the engine fit closely. Meanwhile, reconnect the relevant transmission components of the clutch.
After starting the vehicle, repeatedly press and release the clutch pedal to check if the pedal travel is normal and if the clutch disengages and engages completely and smoothly.
Listen for any abnormal noises in the clutch area during engine operation and gear shifting. If there are problems such as jamming, abnormal noises, or incomplete disengagement, check the installation direction of the clutch release bearing, the position of the release fork, or the lubrication condition, and make timely adjustments and troubleshooting.
These precautions cover safety operation, component specifications, precision control, system compatibility, and commissioning inspection, applicable to mainstream transmissions including manual, automatic, and dual - clutch transmissions (DCT). They ensure smooth clutch disengagement and engagement without abnormal wear after installation.
Park the vehicle securely on a level surface, engage the parking brake, shift into neutral, and disconnect the negative battery terminal. Use a jack combined with safety stands for stable support; never work relying solely on a jack.
Drain the transmission fluid before removing the transmission to prevent leakage - related contamination and safety hazards. For hybrid models, additional high - voltage power - off procedures must be followed.
The new release bearing must be intact, rotate flexibly without jamming. For models with dust covers, do not remove the cover in advance to avoid moisture and impurities from entering.
Clean the flywheel surface, transmission input shaft, and contact areas of the release fork to remove oil stains, iron filings, and rust. If the pilot bearing is loose or makes abnormal noises, replace it simultaneously.
Avoid cleaning with dry brushes as this may cause dust to enter the clutch system. It is advisable to wipe the components with anhydrous alcohol and let them air - dry.
Apply special high - temperature grease (such as CASMOLY L9508) only to the bearing bushing and the contact points between the bushing and the release fork. Use a thin coat; excessive grease is likely to attract impurities, leading to abnormal noises and slipping.
Apply a thin layer of grease to the splines of the clutch disc to prevent installation jamming. It is recommended to replace vulnerable parts like the release fork return spring and snap ring with new ones; reuse is strictly prohibited.
Install the release bearing in the correct direction: the side with protrusions or guide grooves should face the pressure plate release fingers. Some models are marked with "UP" or "FRONT". Reversed installation will result in incomplete disengagement and rapid bearing wear.
Use a special alignment tool (e.g., 09411-25000) or the transmission input shaft to center the clutch disc with the flywheel. This ensures concentricity, avoiding difficulties in installing the input shaft and uneven wear.
Ensure the snap rings and springs connecting the release bearing to the release fork are fully engaged. Use snap ring pliers for installation to prevent detachment. The tension of the return spring must meet the original factory standards to maintain a 3-4mm gap between the bearing and the release fingers at all times.
After installation, manually swing the release fork. The release bearing should move axially smoothly without jamming. For hydraulic release systems, check the master and slave cylinders for leaks and bleed the air from the system.
Pre - tighten the clutch cover bolts in a star or diagonal pattern before final tightening to the torque specified for the model: 15-22 N·m for 1.6L models and 20-27 N·m for 2.0L models. Do not use an impact wrench, as this may deform the pressure plate.
Tighten the bolts connecting the transmission to the engine to the original factory torque to ensure no gaps exist on the mating surfaces and prevent vibration - induced abnormal noises during operation.
References：
The sources are sorted by authority and relevance, with attached original text verification paths and content correspondence instructions:
Vehicle Coverage: Mainstream models including the Cerato, K2, Sportage, and Tucson, covering displacements such as 1.6L, 2.0L, and 2.7L.
Core Chapters: Clutch system disassembly and assembly specifications, torque parameter tables, special tool lists (e.g., 09411-25000 clutch alignment tool), grease model (CASMOLY L9508), and bolt tightening sequences and torque values (15–22 N·m for 1.6L models, 20–27 N·m for 2.0L models).
Key Original Content: Model-specific requirements such as release bearing installation orientation, release fork contact point lubrication, snap ring fixation, gap standards (3–4 mm), and clutch pedal free travel (15–25 mm).
Applicable Scenarios: Clutch position learning and wear compensation procedures after replacing the release bearing/actuator in Dual-Clutch Transmission (DCT) models, including actuator rod length adjustment (e.g., 70.5–71 mm for some 1.6T models) and system initialization steps.
Key Content: Temporary technical requirements such as release bearing snap ring improvements, grease filling quantity revisions, and hydraulic system bleeding specifications for certain model years.
Specification Content: Technical requirements, inspection rules, installation fit accuracy, and service life test standards for release bearings, including general indicators such as fit width deviation between the bearing and release fork, and axial runout.
Core Points: Torque values for bolts connecting the transmission to the engine, inspection and replacement standards for the input shaft pilot bearing, and tension requirements for the release fork return spring.
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