Clutch kit 104711-1 104700-3 C197C375 FOR Fukuda 395*240*406*11

Pre-installation Preparation

1. Vehicle and Tool Preparation

• Park the vehicle on a flat surface, pull the handbrake tightly, lift the vehicle with a jack, and securely support it with safety stands.

• Prepare suitable wrenches, sockets, a torque wrench, as well as a new clutch kit, lithium-based grease, cleaning cloths, and a special locating pin or guide shaft. Ensure the kit’s part number matches the corresponding Foton model.

2. Old Part Removal, Cleaning and Inspection

• First, disconnect the connection between the engine and gearbox, then hoist the gearbox to expose the clutch assembly. Mark the alignment between the clutch cover and flywheel to avoid misalignment later.

• Loosen the clutch cover fixing bolts to release spring tension, then remove the old friction disc, pressure plate, and release bearing.

• Thoroughly clean oil stains and debris from the surfaces of the flywheel and pressure plate with a cleaning cloth. Inspect the flywheel end face—repair or replace it if the warpage deviation exceeds 0.3mm.

• Check the operation of the pilot bearing; add grease or replace the bearing if it jams.

Core Component Installation

1. Install the Friction Disc

• Remember Foton’s rule for friction disc installation: the side with the boss faces the gearbox. For discs marked "TO TRANS", align the marked side with the gearbox.

• Insert the locating pin or special guide shaft into the flywheel’s center hole, then slide the new friction disc onto the pin to ensure concentricity with the flywheel.

• Check the friction disc’s spline sleeve to ensure it slides smoothly on the input shaft. Apply a small amount of special grease (do not over-apply to avoid splashing onto the friction surface).

2. Install and Fasten the Pressure Plate

• Align the pressure plate with the mounting position on the flywheel and fit it onto the friction disc. Temporarily fix the clutch cover bolts by aligning the previously marked positions.

• Use a torque wrench to tighten the bolts in a diagonal crisscross sequence in 2-3 stages. Refer to the maintenance manual of the corresponding Foton model for the final torque; avoid one-time tightening to prevent pressure plate deformation.

3. Assemble Release Components

• Install the release bearing and release fork assembly, then apply lithium-based grease at their connection to reduce wear.

• Check the height of the diaphragm spring tips; ensure the height difference between each tip does not exceed 0.5mm. Calibrate with adjusting screws if the deviation is too large.

Subsequent Reset and Debugging

1. Component Reset

• Pull out the locating pin. When resetting the gearbox, ensure the crankshaft and first shaft are aligned to avoid damaging the spline teeth by forced insertion.

• Fasten the connecting bolts between the gearbox and engine, then reconnect the drive shaft and other components.

• Bleed the clutch system thoroughly if it is hydraulic; adjust the pull rod stroke if it is mechanical.

2. Functional Testing

• Lower the vehicle, start the engine, and adjust the clutch pedal free travel—Foton models generally require a free travel of 20-25mm.

• Perform shift tests to check if the clutch disengages completely and engages smoothly, with no abnormal jitter or noise.

3. Trial Operation Verification

• First, conduct an idle test in neutral, then perform a short-distance light-load trial run of 30-50km.

• Check for clutch slipping, shifting difficulties, or other issues during driving. Resume normal operation only after confirming no abnormalities.

Parts and Pre - installation Preparation

1. Verify Compatibility and Orientation

   The kit must be compatible with the corresponding Foton vehicle model. Check the part number to ensure it matches the engine and transmission models. The clutch driven plate has strict orientation requirements: the side with the boss should face the transmission. For those marked with "TO TRANS", align the marked side with the transmission. Reversing the installation will directly lead to clutch failure.

2. Pre - handle Fluids and Perform Cleaning

   Drain the gear oil in advance before removing the transmission to prevent massive leakage during disassembly that could contaminate components. Clean the oil stains and rust on the surfaces of the flywheel and pressure plate using a special cleaning agent. Never use a dry brush for cleaning, as this may allow dust to enter the internal parts and generate harmful asbestos - containing debris that endangers health. Remove the anti - rust grease from the surface of the new kit to ensure no impurities remain on the friction surfaces.

Core Installation Operations

1. Precise Positioning to Prevent Misalignment

   Insert a dedicated guide shaft or the transmission input shaft into the central hole of the flywheel, then mount the driven plate onto it to ensure concentricity with the flywheel. This avoids difficulties in installing the transmission input shaft later. During installation, align the assembly marks on the clutch cover and the flywheel. If there are balance washers, install them in their original positions.

2. Standardized Fastening with Torque Control

   After installing the pressure plate, use a torque wrench to tighten the bolts in a diagonal cross pattern through 2 - 3 stages. Refer to the maintenance manual of the corresponding Foton vehicle model for the specific torque value. Avoid tightening the bolts all at once, as this may cause deformation of the pressure plate. Never use a pneumatic impact wrench for fastening, as it may result in torque loss of control.

3. Proper Lubrication Without Contamination

   Apply lithium - based grease to the connection between the release fork and the release bearing, as well as the moving parts of the release lever. Fill the release bearing with grease to approximately 1/2 - 2/3 of its internal cavity volume. A small amount of special grease can be applied to the splines, but excess grease must be wiped off to prevent it from splashing onto the friction surfaces and causing slipping.

Component Inspection and Calibration

1. Check for Component Wear and Tear

   Inspect the end face of the flywheel. If the warpage deviation exceeds 0.3mm, repair or replace the flywheel. Check whether the release bearing operates smoothly; if it jams, replace it or add lubricating grease. Meanwhile, inspect the hub rivets and shock absorber of the driven plate for wear or damage, and check the diaphragm spring for deformation. Replace any faulty components promptly.

2. Calibrate Key Parameters

   Ensure that the height difference between the top ends of the diaphragm spring does not exceed 0.5mm. If the deviation is excessive, calibrate it using the adjusting screws. If the compression springs have inconsistent elasticity, arrange them symmetrically. For springs with insufficient elasticity but no cracks, compensate by adding a metal washer (no thicker than 2mm) to the spring seat.

Subsequent Commissioning and Safety Measures

1. Complete Component Reset and Commissioning

   For hydraulic clutches, fully bleed the clutch system after installation. For mechanical clutches, adjust the pull rod stroke and finally set the free travel of the clutch pedal within the reasonable range suitable for the Foton vehicle model.

2. Ensure Safety and Conduct Test Runs

   Securely support the transmission with a stand during disassembly and installation to prevent it from falling and causing injury. After installation, start the engine to test gear shifting, and observe whether the clutch disengages and engages normally. Subsequently, conduct a short - distance light - load test run of 30 - 50 kilometers. Only resume normal operation after confirming there are no issues such as slipping or abnormal noise during driving.

References：

PCauto

• This platform features multiple articles on the installation of clutch three-piece kits, covering key points consistent with the content you mentioned.

• For example, it specifies using a dedicated guide tool to ensure concentricity between the friction disc and flywheel during installation, tightening pressure plate bolts in stages in a diagonal sequence, using a water-moistened cloth for cleaning to avoid harmful dust, and conducting a test drive after installation.

• These details highly align with the Foton clutch installation precautions you previously learned.

Autohome

• Its vehicle maintenance Q&A section contains a wealth of content related to clutch installation.

• Key points include emphasizing the clear installation direction of the clutch disc, aligning assembly marks when installing the pressure plate, using a torque wrench to fasten bolts to the specified torque, and adjusting the clutch pedal free travel and testing smooth gear shifting after installation.

• These are core points of the installation method and precautions you described, serving as important references for Foton vehicle installation operations.