clutch release bearing 41420-5H510 414205H510，41420T00030 ME615141，ME609370，ME615140，VKC3587 ME624678，RCT4700SA，500131110 FOR Hyundai H-1/H100 Bus/Satellite 2.5 TD

Installation Method for Clutch Release Bearing of Hyundai Vehicles

1. Remove the Transmission Assembly: Refer to the manual transmission removal section in the vehicle maintenance manual, and remove the transmission from the vehicle.
2. Remove the Old Release Bearing (If Not Completed in Advance): If the clutch is attached to the flywheel, use circlip pliers to remove the release bearing. First, rotate the flywheel to a position where the circlip is easy to access. Place the circlip pliers under the wave washer so that they are centered on the circlip. Press down on the release bearing and expand the circlip. Pull out the release bearing and remove it while the circlip is expanded.
3. Pre-Installation Preparation: Apply universal grease (e.g., CASMOLY L 9508) to the splines of the clutch disc, with an amount of approximately 0.2 grams.
4. Install the Clutch Disc Assembly: Use a special tool (e.g., 09411-11000) to install the clutch disc assembly on the flywheel.
5. Install the Clutch Cover Assembly: Install the clutch cover assembly on the flywheel and temporarily tighten the bolts in a diagonal direction, one or two turns at a time. The tightening torque is 15-22 Nm.
6. Install the Release Bearing: Align the release bearing with the release fork, then install it on the bushing of the housing. Apply an appropriate amount of universal grease to the bearing bushing and the contact surface of the release fork.
7. Install the Release Lever: Install the release lever on the release fork.
8. Reinstall the Transmission Assembly: Reinstall the transmission assembly back onto the vehicle.
9. Check Alignment: Push the release lever in a specific direction. If a "click" sound is heard, it indicates that the release bearing is correctly aligned with the clutch cover. Meanwhile, the operating range of the release lever should be 3 degrees or less. If it exceeds 3 degrees, the release bearing cannot be correctly aligned with the clutch cover, and the release lever needs to be pushed again.

Precautions for Installing Clutch Release Bearing of Hyundai Vehicles

1. Safety Operation Baseline: Ensure the vehicle is turned off, the parking brake is engaged, and the negative battery terminal is disconnected before starting work. When removing or installing the transmission, use a dedicated bracket to stably support the engine (the engine mounts of some Hyundai models are relatively soft). This prevents component damage from falling and avoids safety accidents.
2. Accessory Compatibility Verification: Strictly check that the release bearing model matches the vehicle (e.g., Hyundai Elantra corresponds to bearing number 41421-26000, Sonata corresponds to 41421-3K000). Inspect that the bearing rollers have no jamming or abnormal noise, and the sealing ring is intact. This avoids clutch failure after installation due to mismatched specifications.
3. Grease Usage Specifications: Apply the specified grease (Hyundai recommends universal grease such as CASMOLY L 9508) only to the contact area between the release bearing and release fork, and the splined hole of the clutch disc. Control the amount to approximately 0.2 grams for the splined area. Never let grease flow into the bearing interior or contaminate the clutch friction surface, as this will cause slipping and poor disengagement.
4. Bolt Tightening Requirements: When installing the clutch cover assembly, tighten the bolts evenly in 2-3 diagonal sequences. Strictly follow the specified torque of 15-22 N·m (refer to the vehicle maintenance manual). Avoid over-tightening (which causes pressure plate deformation) or under-tightening (which leads to uneven force on the release bearing and abnormal noise).
5. Alignment of Release Bearing and Fork: When installing the release bearing, ensure it is fully aligned with the guide groove of the release fork, and push it into place gently (most Hyundai release forks are made of resin; do not tap hard to prevent cracking). After installation, push the release fork to check if the bearing can smoothly contact the pressure plate’s release fingers without jamming or deviation.
6. Use of Special Tools: When installing the clutch disc assembly, must use Hyundai’s original factory special positioning tool (e.g., 09411-11000) to center the clutch disc. This avoids uneven contact between the release bearing and the pressure plate’s release fingers due to positioning deviation, which accelerates bearing wear.
7. Alignment Check Standards: After installation, push the release lever— a "click" sound confirms the release bearing is correctly aligned with the clutch cover. Meanwhile, check the release lever’s operating range; it must be within 3 degrees. If it exceeds 3 degrees, re-adjust, otherwise the clutch will not disengage completely and gear shifting will be difficult.
8. Transmission Reassembly Details: When reinstalling the transmission, ensure the input shaft can be smoothly inserted into the splined hole of the clutch disc. If there is excessive resistance, recheck the clutch disc’s positioning. After reassembly, connect the negative battery terminal and press the clutch pedal 3-5 times to bleed air from the hydraulic system, avoiding soft pedal feel and poor disengagement.
9. Key Post-Installation Tests: Start the engine, press and release the clutch pedal at idle speed, and listen for "buzzing" abnormal noise (a sign of bearing failure). Engage all gears to test smooth shifting, ensuring no gear shifting jamming (incomplete disengagement) or starting vibration (bearing alignment deviation).
10. Synchronous Inspection of Wear Parts: When installing the release bearing, simultaneously inspect the release fork bushing and the clutch cover’s release fingers (most Hyundai models use 3-point distribution). Replace them if worn or deformed to prevent rapid damage to the new bearing due to aging associated components and reduce secondary maintenance.

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