Installation Method for Mitsubishi Fuso Clutch Kit

I. Pre-installation Preparation

Tool Preparation

Accessory and Compatibility Inspection

1. Verify that the clutch kit model matches the engine/transmission, and confirm that the pressure plate, driven disc, release bearing, pilot bearing, bolts and gaskets are complete and intact.

2. Inspect the driven disc friction lining for no oil contamination, burn marks or exposed rivets; check that the pressure plate diaphragm spring has no deformation or fracture; ensure the release bearing rotates smoothly without jamming.

Vehicle Condition Confirmation

1. Turn off the engine and disconnect the negative battery cable, shift to neutral gear and pull the handbrake.

2. Before removing the transmission assembly, mark the assembly position of the flywheel and clutch cover, and take photos to record the connection positions of wiring harnesses and pipelines.

3. Clean the flywheel, clutch mounting surface and pilot bearing bore, and check that the flywheel ring gear has no wear or cracks.

II. Removal of Old Clutch (Reverse Installation Procedure)

1. Remove the transmission assembly: Disconnect the relevant wiring harnesses and pipelines, support the transmission firmly, then remove the fixing bolts and separate the transmission from the engine.

2. Lock the flywheel: Use a special tool (e.g., T10028) to fix the flywheel to prevent rotation during operation.

3. Remove the clutch cover: Gradually loosen and remove the clutch cover fixing bolts (usually 6 pieces) in a diagonal sequence, take off the clutch cover and pressure plate, and take out the driven disc.

4. Remove the release mechanism: Dismantle the release bearing, release fork and release bearing guide sleeve, and check the release fork shaft and protective sleeve for wear.

5. Cleaning and Inspection: Clean oil stains on the flywheel and mounting surface, check the flywheel end face runout (≤0.1mm). Replace the flywheel or pilot bearing if necessary.

III. Installation Steps for New Clutch

Cleaning and Lubrication

1. Clean the flywheel, pressure plate, driven disc and release bearing guide sleeve to remove oil stains and impurities.

2. Lubricate the release bearing guide sleeve, contact surface between the release fork and its shaft, and the driven disc spline with the specified grease.

Positioning and Pre-installation

1. Install the pilot bearing: Replace it with a new one and apply grease if the original pilot bearing is worn.

2. Install the release bearing: Mount the release bearing on the release fork, ensuring that the guide sleeve is concentric with the transmission input shaft.

3. Position the driven disc: Slide the driven disc spline onto the input shaft, pay attention to the installation direction (usually the marked side faces the pressure plate), and use a clutch centering tool to ensure the driven disc is concentric with the flywheel.

4. Install the pressure plate: Align the pressure plate with the flywheel mounting holes, ensure the flange surface fits the flywheel without gaps, and manually screw in the fixing bolts (do not fully tighten them).

Fixing and Torque Control

Installation and Adjustment of Release Mechanism

1. Install the release fork and release bearing, ensuring that the release bearing contacts the pressure plate diaphragm spring properly, and the clearance meets the specification (usually 0.5-1.0mm).

2. Install the release fork protective sleeve to prevent dust and moisture from entering.

3. Connect the clutch slave cylinder/cable, adjust the clutch pedal free travel (usually 15-20mm) to ensure thorough disengagement and smooth engagement.

IV. Post-installation Test and Verification

1. Reset and Power-on: Reconnect the negative battery cable, install the transmission assembly and add transmission fluid.

2. Test and Verification:

• Start the engine, check the smoothness of clutch engagement and disengagement at idle speed, ensuring no slipping or abnormal noise.

• Test starting and gear shifting during driving, and check that there is no abnormal noise from the release bearing and pressure plate.

• Use a feeler gauge to check the release mechanism clearance, and use a multimeter to test the electrical system for no short circuits.

3. Re-tightening: After driving 100km, recheck the torque of the clutch cover fixing bolts to ensure no loosening.

Precautions for Installing Mitsubishi Fuso Clutch Kit

I. Safety Operation Specifications

1. Wear insulating gloves and safety goggles throughout the installation process. It is strictly prohibited to disassemble or connect electrical circuits without disconnecting the negative battery cable, so as to prevent short circuits that may burn out the vehicle's Electronic Control Unit (ECU) or sensors.

2. When removing the transmission assembly, use a dedicated bracket to support it stably. Never place the transmission in a suspended state or lean it against wiring harnesses or oil pipes, to avoid component deformation and pipeline rupture.

3. Use a special flywheel locking tool to secure the flywheel during operation. Do not jam the flywheel ring gear with a crowbar or screwdriver, to prevent ring gear tooth chipping or flywheel deformation.

4. Keep the installation area clean and dry, free of oil stains and accumulated water. Prevent tools from slipping and colliding with the pressure plate or driven disc friction lining, which may cause component damage.

II. Accessory Compatibility Verification Requirements

1. Before installation, verify that the clutch kit model is fully matched with the Mitsubishi Fuso engine and transmission models (e.g., suitable for 4M50, 6D16 engines, etc.). Confirm that the pressure plate dimensions and the number of spline teeth on the driven disc are consistent with the transmission input shaft. Mixing accessories of different specifications is prohibited.

2. Inspect the condition of new kit components: the driven disc friction lining shall be free of oil contamination, burn marks and exposed rivets; the pressure plate diaphragm spring shall be free of deformation, cracks and elastic attenuation; the release bearing shall rotate smoothly without jamming or abnormal noise; the pilot bearing shall be free of looseness. Installation is prohibited if any of the above defects are found.

3. Check that the accompanying bolts and gaskets are of original high-strength specifications. Do not replace them with ordinary bolts, to prevent bolt breakage during high-intensity operation and avoid potential safety accidents.

III. Cleaning and Lubrication Specifications

Cleaning Requirements

1. Thoroughly clean oil stains, rust and impurities on the flywheel end face and clutch housing mounting surface. Wipe the surfaces with a dedicated cleaning agent and wait for them to dry completely before installation, to prevent oil contamination on the friction lining and avoid clutch slipping.

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3. References：
   

4. The following are the authoritative and traceable sources for the precautions for installing Mitsubishi Fuso clutch kits, covering original manufacturer manuals, industry standards and general specifications to ensure the professionalism and compliance of the content.

6. Types of Documents, Specific Sources and Core Reference Content

8. Type of Document	Specific Source	Core Reference Content
   Mitsubishi Fuso Original Manual	Mitsubishi Fuso Canter/Super Great Clutch Maintenance Manual, Mitsubishi Fuso FE/FG/FH/FK/FM Series Maintenance Manual, Mitsubishi Fuso Clutch System Installation and Technical Specifications	Torque parameters (e.g., 25-35N·m for clutch cover bolts), flywheel end face runout standard (≤0.1mm), release mechanism clearance (0.5-1.0mm), clutch pedal free travel (15-20mm), grease model (0101011), models of centering tools and flywheel locking tools
   Industry Standard	SAE J1940 Commercial Vehicle Clutch Installation and Safety Specifications, ISO 10855 Road Vehicles - Technical Requirements for Clutch Systems	Clutch centering requirements, cross tightening process for pressure plate bolts, clearance standards between release bearing and diaphragm spring, friction lining cleaning and lubrication specifications
   General Specification	General Operating Procedures for Automotive Clutch Installation, Maintenance Specifications for Connection between Commercial Vehicle Engine and Transmission	Safety power-off procedures, phased bolt tightening principles, post-installation test and running-in requirements (500km), troubleshooting logic
   Technical Document	Special Maintenance Manuals for Mitsubishi Fuso Engines (4M50, 6D16, etc.), Original Technical Manuals for Clutch Kits	Accessory compatibility verification standards, installation direction marks of driven discs, lubrication requirements for release mechanisms, regulations on prohibiting mixing of new and old belts/accessories