clutch kit 30002857 41300-02857 4130002857,41100-02850，30002857 41300-02857， 4130002857，30002857 41100-02855 S1,41100-02880,41300-02850 S1 FOR Hyundai Kia

Pre-installation Preparation

1. Tool Preparation: Prepare tools such as a jack, jack stands, wheel chocks, wrenches, and Phillips screwdrivers. If conditions permit, also prepare a vehicle frame, transmission hanger, and special tools like a four-jaw socket wrench.

2. Vehicle Preparation: Park the vehicle on a flat and safe surface, engage the handbrake, and place bricks or other objects under the front and rear tires to prevent the vehicle from moving.

3. Component Inspection: Check whether all components of the clutch kit are intact and ensure they match the vehicle's model and specifications. Meanwhile, clean the installation area to remove oil stains and impurities.

4. Understand Vehicle Model Information: Confirm the specific vehicle model. Clutch installation may have slight differences among different Hyundai and Kia models, such as the tightening torque of bolts.

Installation Steps

1. Remove Relevant Components: Use the jack to lift the vehicle and support it stably. Remove the connecting components between the transmission and the engine, including the drive shaft, and then detach the transmission.

2. Remove the Old Clutch: Use a wrench to remove the clutch bolts, take off the clutch pressure plate and driven plate from the flywheel, and carefully inspect the crankshaft pilot bearing for damage. Replace it promptly if damaged.

3. Install the New Clutch Kit

• Apply Grease: Apply an appropriate amount of grease (e.g., CAS MOLY L9508) to the spline part of the clutch driven plate and the spline part of the transmission input shaft as required. The application amount varies by model—for example, 0.1-0.2g for Hyundai Tucson 1.6T-GDI models, and 0.1-0.3g for 2.0 MPI and 1.6 TCI models.

• Install the Driven Plate: Pay attention to the direction of the driven plate. The side with the boss faces the transmission, and the side without the boss faces the flywheel. Alternatively, install it according to the marks "T/M SIDE" (facing the transmission) and "FLYWHEEL SIDE" (facing the flywheel) on the driven plate. Use a special tool (e.g., 09411-1P000) to align the driven plate with the pilot bearing of the transmission shaft, ensure the flywheel and the driven plate are concentric, and then install them on the flywheel.

• Install the Clutch Cover: Align the clutch cover with the installation marks, install the clutch cover bolts, and tighten them in several steps according to the specified torque. The tightening torque differs by model—for example, 14.7-21.6N・m for Hyundai Tucson 1.6T-GDI models, and 11.8-14.7N・m for 2.0 MPI and 1.6 TCI models. Tighten the bolts sequentially in a diagonal direction to prevent distortion, vibration of the clutch cover, and lifting of the pressure plate.

• Install the Release Fork and Release Bearing: Apply lithium-based grease to the connection between the release fork and the release bearing, then install them in the corresponding positions.

4. Install the Transmission: Reinstall the transmission back to the vehicle and connect other components between the transmission and the engine.

5. Adjust the Clutch Pedal: After installation, inspect and adjust the height and free travel of the clutch pedal to meet the vehicle's standard requirements. Generally, the free travel of the clutch pedal should be adjusted to 15mm-25mm.

Post-installation Inspection

Tools and Accessories

• Use Special Tools: When disassembling and assembling clutch components, special tools must be used to prevent the clutch disc from falling off. Do not clean with a dry brush to avoid generating dust.

• Select High - Quality Accessories: Try to choose original factory or reliable - quality clutch accessories. Avoid using products from unknown brands to prevent problems.

Pre - installation Inspection

• Check Component Condition: Carefully check the surfaces of the clutch cover, clutch disc, release bearing and other components for wear, cracks or oil stains. Measure the thickness of the clutch disc and the depth of the rivets. If they do not meet the standard values, they should be replaced.

• Clean Component Surfaces: Thoroughly clean the surfaces of the flywheel and pressure plate with fine - grit sandpaper or emery cloth to ensure that all oil stains or grease have been removed.

Installation Process

• Pay Attention to Installation Sequence and Direction: The clutch disc has a direction requirement. The surface marked "T/M SIDE" should face the transmission. If it is installed in the wrong direction, it may cause transmission shifting errors or abnormal noises. When installing the clutch cover bolts, be careful not to bend or twist the bolts. They should be tightened gradually in a diagonal direction.

• Apply Grease Correctly: Apply an appropriate amount of multi - purpose grease to the release fork assembly, the groove of the release bearing, the contact surface of the lever and the splines of the input shaft. However, do not apply too much, as it may cause the clutch to slip or vibrate.

• Align the Pilot Bearing: When installing the clutch, use a special tool or the transmission input shaft to align the driven disc with the pilot bearing of the transmission shaft to ensure the accurate installation position.

• Tighten Bolts and Check Torque: When installing the clutch pressure plate assembly, the pressure plate must be in contact with the flywheel before tightening the bolts. Tighten the bolts gradually in a diagonal direction to ensure that the tightening torque meets the requirements. For example, some models require a tightening torque of 25 N·m.

Post - installation Adjustment and Inspection

• Adjust Clutch Clearance: The clutch clearance needs to be adjusted to the standard value. For example, the standard clearance value of the K1 and K2 clutch discs of the Kia K3 is 1 mm. It can be measured with a feeler gauge and the pull - rod distance can be adjusted by turning the adjusting screw to adjust the clutch clearance.

• Check Hydraulic System: After installation, check the clutch hydraulic system for leaks to ensure the normal operation of the hydraulic system. At the same time, ensure that the free play of the clutch pedal is within the specified range, such as 15 - 25 mm.

• Conduct Test Drive Inspection: After installation, do not rush to drive on the road. Press the clutch several times to check if the shifting is smooth. After ensuring there are no problems, conduct a test drive. During the test drive, pay attention to observing the working state of the clutch, such as whether there are abnormal noises or slipping phenomena。

• References：
  

• According to the text content and search results, this passage may be from an automotive repair manual or a related automotive repair website.
• From the search results, the article on Autohome mentions some precautions for the installation of the clutch kit of Hyundai - Kia cars. For example, when replacing the clutch of a Kia K3, special tools should be used, the direction of the clutch disc should be noted, and the clutch clearance should be adjusted. In addition, the content on websites such as kiamanual.com, hsonatalf.org, and tucsondatamanu.com also involves the installation methods and precautions of the clutches of Kia and Hyundai cars, including the replacement requirements of clutch discs and pressure plates, the use of lubricating grease, and the tightening torque of bolts.
• Therefore, the content you provided about the installation precautions for the Hyundai - Kia car clutch kit may be compiled by integrating the relevant information from automotive repair manuals and websites such as Autohome and kiamanual.com.