Clutch kit 1600200BED01A，1600100ED01 ZM015B1601307 1600200BED01A，1600100ED01，62RCT3533F0 25GW001，GWC802 KF-024，JMD202 for Great Wall GW4D20

Pre-installation Preparation

• Vehicle Preparation: Turn off the vehicle and disconnect the power supply, pull the handbrake tightly. Lift the vehicle steadily with a jack and secure it with special brackets to prevent shaking during operation. Wait for the engine to cool down completely to avoid burns from high-temperature components.

• Accessories and Tools Preparation: Confirm that the new clutch kit is compatible with the vehicle model, prefer original accessories. Check the kit for no housing damage, and ensure the clutch disc surface is flat and free of wear. Prepare tools and consumables such as wrenches, sockets, torque wrenches, cleaning cloths, and hydraulic oil.

• Hydraulic System Preparation (if applicable): For vehicles with a hydraulic clutch system, loosen the clutch master cylinder bolts in advance and drain the hydraulic oil to prepare for subsequent disassembly.

Removing the Old Kit and Cleaning Inspection

1. First remove the vehicle tires, then gradually disassemble the subframe and other obstructive components to remove the gearbox and access the clutch kit inside the flywheel housing between the engine and gearbox.

2. Remove the fixing bolts of the clutch cover, carefully take out the old clutch disc and pressure plate, then remove the old release bearing. Handle with care to avoid damaging surrounding components such as the flywheel and gearbox input shaft.

3. Thoroughly clean the flywheel surface, the interior of the flywheel housing, and related mounting contact surfaces with a cleaning cloth to wipe off residual oil, metal debris, and dust. Check the flywheel surface for scratches and deformation; repair or replace it in a timely manner if the damage is severe.

Installing the New Clutch Kit

1. First install the release bearing. Use the old push rod (bowl head) for auxiliary positioning to ensure it is properly installed with uniform force, avoiding abnormal noise or incomplete disengagement in subsequent use.

2. Place the new clutch disc, align the marks, ensure the flat side faces the engine, and align the center sleeve of the clutch disc with the gearbox input shaft for precise installation.

3. Install the clutch pressure plate, align it with the clutch disc, and hand-tighten the fixing bolts without fully tightening them. Use a torque wrench to evenly tighten the bolts in diagonal order in stages to avoid uneven force on the pressure plate leading to abnormal operation of the clutch disc.

4. Lift the clutch-related protective belt, secure the cotter pins, reconnect the previously removed wiring harness connectors, and adjust the clutch wiring harness to ensure a reasonable layout that does not affect component operation.

Resetting Components and Debugging

1. Reinstall the gearbox, subframe, tires, and other components in the reverse order of disassembly. Then add new hydraulic oil to the clutch hydraulic system and bleed the air from the system to ensure smooth hydraulic circuit.

2. Check all fixing bolts with a torque wrench to confirm they meet the specified torque and are free of loosening. Adjust the clutch clearance to ensure smooth pedal operation and avoid slipping or incomplete disengagement.

Post-installation Testing

1. After starting the vehicle, step on the clutch pedal repeatedly to feel if the pedal feedback is smooth without jamming or abnormal noise.

2. Conduct start-up and gear-shifting tests to observe if the clutch engages smoothly without shaking or slipping. If problems such as difficulty in shifting or poor power transmission occur, stop the vehicle immediately for inspection, checking the tightness of bolts, the installation direction of the clutch disc, and other potential issues.

1. Bottom Lines for Safe Operation

• After lifting the vehicle, it must be fixed with special brackets. Never rely solely on a jack to prevent the vehicle from falling. Disconnect the negative battery terminal throughout the process to avoid short circuits of electrical components.

• Wear protective gloves and goggles during operation to prevent scratches from metal components such as the flywheel and pressure plate. At the same time, stay away from high-temperature areas of the engine to avoid burns.

• When disassembling/installing heavy components such as the gearbox, use a jack or hoisting tool for assistance. Never lift them by hand to prevent injury from falling components.

2. Requirements for Installation Accuracy

• The installation direction of the clutch disc must be correct. Strictly align the surface marks and ensure the flat side faces the engine. Reversing the installation will lead to clutch disengagement failure and difficulty in shifting.

• The pressure plate fixing bolts must be tightened in accordance with the principle of "diagonal step-by-step tightening". Use a torque wrench to fasten them to the torque specified by the vehicle model (25-35N·m for most Great Wall models, subject to the maintenance manual) to avoid uneven force on the pressure plate.

• The release bearing must be installed in place, ensuring tight fit with the shift fork without gaps. After installation, manually rotating the bearing should be smooth without jamming; otherwise, abnormal noise or incomplete disengagement is likely to occur.

3. Component Compatibility and Cleaning

• The new clutch kit must be compatible with the specific Great Wall vehicle model. Prefer original or supporting brands. Verify that the clutch disc size and pressure plate specifications match the flywheel to avoid malfunctions caused by incompatible accessories.

• Thoroughly clean the flywheel surface and clutch mounting surface before installation to remove oil, metal debris, and rust. If the flywheel has scratches or warpage (flatness error exceeding 0.3mm), it needs to be ground, repaired, or replaced.

• After replacing the kit for hydraulic clutch systems, completely bleed the air in the oil circuit and add hydraulic oil consistent with the original vehicle specifications. This prevents soft pedals and weak disengagement caused by air in the oil circuit.

4. Specifications for Commissioning and Inspection

• After installation, the clutch clearance must be adjusted to ensure the pedal free travel meets the vehicle model standard (generally 5-15mm). The pedal should return smoothly without jamming when stepped on.

• After the first start, step on the clutch pedal 10-15 times in neutral to run-in the release mechanism before conducting start-up tests. Avoid direct high-load operation.

• If clutch shaking, slipping, or shifting difficulty occurs during testing, prioritize checking the clutch disc direction, pressure plate bolt tightness, and release bearing installation status. Do not drive forcefully.

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