Clutch kit 5-87610-204-0 587610204-0 5-87610204-0 ， 5876102040 587610204-0 5-87610204-0 ， 5876102040 587610204-0 5-87610204-0 ， 5876102040 FOR Isuzu

The following are the general installation steps for the Isuzu clutch kit: •  Preparation Work: Park the vehicle on a flat and safe surface, pull up the handbrake, and ensure the vehicle is turned off. Prepare the new Isuzu clutch kit (including the clutch disc, pressure plate, release bearing, etc.), wrenches, sockets, a jack, safety stands, and other tools.  •  Removing Related Components: Lift the vehicle with a jack and securely support it with safety stands to obtain sufficient operating space. Then, remove the connecting components between the drive shaft and the transmission; this usually involves removing the drive shaft nut to separate the drive shaft from the transmission. Next, remove the connecting bolts and other components between the transmission and the engine, separate the transmission from the engine, and place it properly.Removing the old clutch kit: Before removing the clutch cover assembly and flywheel assembly, make assembly marks to ensure accurate reinstallation when fitting the new components. Then, gradually loosen and remove the fixing bolts of the clutch cover assembly in a diagonal direction, and take off the old clutch pressure plate and clutch disc. Meanwhile, check if the flywheel surface is flat, worn, or damaged; if there are any issues, repair or replace it in a timely manner.  •  Cleaning and inspection: Use a clean cloth to thoroughly remove oil stains, rust, and debris from the flywheel, pressure plate mounting surface, and transmission input shaft. Check if the transmission input shaft is worn or loose; if there are any abnormalities, handle them accordingly. Also, inspect each component of the new clutch kit for damage and ensure it matches the vehicle's model and specifications.Installing the new clutch disc: First, add an appropriate amount of lubricating oil to the pilot bearing of the flywheel to make the bearing run more smoothly. Then, place the new clutch disc on the transmission input shaft, ensuring that its intermediate spline is accurately aligned with the input shaft. At the same time, pay attention to the installation direction of the clutch disc; usually, the side marked "flywheel side" should face the flywheel.  •  Installing the clutch pressure plate: Align the clutch pressure plate with the installation marks, install it on the flywheel, and screw on the fixing bolts. Tighten the pressure plate bolts evenly in multiple steps in a diagonal direction to reach the tightening torque specified by the manufacturer.Install the clutch pressure plate: Align the clutch pressure plate with the installation marks, install it on the flywheel, and screw on the fixing bolts. Tighten the pressure plate bolts evenly in multiple steps in a diagonal direction to the tightening torque specified by the manufacturer.  •  Install the release bearing and release fork assembly: Apply an appropriate amount of lithium-based grease to the connection between the release fork and the release bearing to reduce friction. Then, install the release bearing onto the release fork, ensuring it is properly seated and can rotate flexibly. Next, install the release fork assembly in the corresponding position of the transmission and connect the relevant operating mechanisms.  •  Install the transmission: Reinstall the transmission onto the engine and tighten the connecting bolts. Then, reinstall the drive shaft to its original position and tighten the drive shaft nuts.Adjustment and Inspection: After installation, it is necessary to inspect and adjust the clutch pedal, including adjusting the pedal height and free travel, to ensure that the pedal operates smoothly, responds sensitively, and that the pedal travel and force meet the vehicle's technical requirements. Finally, start the vehicle and conduct an actual test to check whether the clutch engages and disengages normally, and whether there are any abnormal noises, vibrations, or incomplete disengagement issues.

Isuzu Clutch Kit Installation Precautions I. Safety Operation Specifications •  Vehicle Fixation Safety: The vehicle must be supported using jacks and safety stands with matched rated loads. It is strictly prohibited to work relying solely on jacks; wheels must be chocked with triangular wooden blocks to ensure no risk of vehicle sliding.  •  Tools and Protection: Use qualified tools such as torque wrenches and special sockets to avoid component damage or operational errors caused by improper tools; wear gloves and goggles to prevent oil splashing and mechanical injuries.  •  Power Off and Pressure Relief: Disconnect the negative pole of the vehicle battery before installation to avoid accidental activation of the electrical system; if a hydraulic clutch is involved, release the pressure in the hydraulic system first to prevent oil spraying.Requirements for Components and Installation Accuracy •  Component Matching: Confirm that the new clutch kit (pressure plate, clutch disc, release bearing) is completely compatible with the specific vehicle model (such as Isuzu D-MAX, Ruimai, etc.), and check that the part number is consistent with the original factory specifications.  •  Cleaning and Lubrication: The mounting surfaces of the flywheel and pressure plate must be thoroughly cleaned of oil stains, rust, and wear debris to ensure a tight fit; apply high-temperature lithium-based grease to the contact areas of the release bearing and release fork to avoid dry friction noise.Bolt tightening standards: The pressure plate fixing bolts must be evenly tightened diagonally in multiple steps, strictly following the torque value specified by the manufacturer (usually 25-35N・m, subject to the vehicle manual for details) to prevent deformation of the pressure plate due to uneven force.  •  Clutch disc direction: Ensure that the side of the clutch disc marked "flywheel side" faces the flywheel. Incorrect installation (reversed direction) will result in incomplete clutch disengagement; calibrate the spline clearance through the transmission input shaft to ensure proper installation.Inspection and Handling of Key Components •  Flywheel Inspection: Check the flatness of the flywheel surface before installation. Measure using a straightedge and feeler gauge. The end face runout must be controlled within 0.2mm. If there are scratches, grooves, or warping, the flywheel must be turned or replaced.  •  Condition of the Pilot Bearing: Check the rotational flexibility of the flywheel pilot bearing. If there is jamming or abnormal noise, it must be replaced in a timely manner; otherwise, it will cause wear on the input shaft or abnormal clutch operation.  •  Hydraulic System Handling (Hydraulic Clutch): After installation, bleed the hydraulic system to avoid residual air in the pipeline causing a soft pedal or incomplete disengagement. Check the master and slave cylinders for leaks and promptly replenish brake fluid that meets specifications (such as DOT4).

References：Regarding the content I previously wrote about the installation of Hino clutch friction plates, I did not directly cite specific sources. It was mainly a synthesis of general knowledge and experience from the following aspects: • Automotive professional websites: Platforms such as Autohome and Pacific Auto Network have many articles and Q&A sections on automobile clutch maintenance and installation. For example, relevant content on Pacific Auto Network mentions that when installing a clutch plate, assembly marks should first be made on the clutch cover assembly and flywheel assembly, and when installing a new clutch plate, the splines should be aligned with the drive shaft, with the side having a boss facing the transmission, etc. Autohome also shares similar installation key points, which all provided me with basic references.Automobile Repair Manual: Although there is no official repair manual for a specific model of Hino automobile, the specifications and requirements for clutch system installation in general manuals in the field of automobile repair, such as cleaning requirements, torque standards, component inspection methods, etc., play a significant guiding role in organizing relevant content.  •  Automobile Repair Professional Books: Some professional books on automobile repair systematically explain the installation steps and precautions for clutch components, including the installation direction of friction plates, lubrication requirements, etc., which are also important bases for me to organize the content.