how to replace a clutch

The replacement method of the clutch is to use the bracket raising device and use the trolley jack to remove the gearbox. It is strongly recommended to use a clutch alignment tool, otherwise you may spend a lot of time trying to align the clutch plate and input shaft spline.

Reasons for clutch replacement.

What is the manufacturing method of the clutch disc?

Problems and solutions during clutch replacement.

Reasons for clutch replacement.

When the engine is idling, although the clutch pedal is fully depressed, it is difficult to shift gears and the gearbox makes noise. At this time, you must remove the clutch bottom cover, put the gearbox in neutral, and then press the clutch to the end. Then, use a screwdriver to move the driven plate. If it can be easily dialed out, it means the clutch has been disengaged. If it cannot be dialed out, it means that the clutch is not completely disengaged.

Therefore, it is necessary to check whether the height of the separation rod is the same and whether it is too low. If the separation is not completed after the above adjustment is normal, then only remove and replace the clutch, check whether the driven plate is reversed, whether the axial movement is difficult, whether the main driven plate is warped, whether the separation rod screw is loose, and whether the floating pin falls off.

What is the manufacturing method of the clutch disc?

The basic material selected for the clutch is iron ore. The iron ore is melted in a high-temperature furnace, and then a curing agent is added. The curing agent can solidify the residue and waste. The curing agent is ferrous sulfate, the reaction time is 100-230 minutes, and the pressure is 1-2 standard atmospheres.

The solidified residue is discharged through the drain valve, and the metal solution that has been removed is poured out from the upper mouth. After being poured out, it is cooled, and then tested by the inspection line. The qualified clutch is placed in the cold rolling mill for repeated cold rolling to strengthen its metal strength to the austenite standard, and then smash into a disc shape as a blank.

The surface of the blank uses wire-cut grooves with layers and adds surface preservatives. The clutch disc made by this manufacturing method has a high-strength surface, is very resistant to friction, and has a long life!

Problems and solutions during clutch replacement.

Neutral gear changes and engine speed increase without increasing speed, which are undoubtedly signs of clutch wear and slippage：

First, remove the battery, remove the gear lever (two bolts) in the cab, take the car off the ground, and loosen the clutch cable from the fork lever in the dust cover on the side of the gearbox. The clutch cable needs to be loosened by loosening the adjusting nut at the firewall in the engine compartment.

Next, disconnect the sensor wire from the gearbox, then loosen and disconnect the handbrake cable so that the gearbox can be removed. The tail shaft must come out, which is a direct disassembly of the four nuts and bolts.

Then, a portion of the exhaust gas must be discharged to aid entry. Due to the continuous expansion and contraction of dust, rust, and hot exhaust pipes, the bolts on the exhaust holes are usually difficult to remove. Penetrants (such as WD40) can help loosen difficult bolts.

When everything goes well, remove the starter motor, and then begin to remove the flared housing bolts. Some bolts may be difficult to access and require additional tools such as long extension rods, rotary joints and breaker rods.

Next, remove the gearbox. If you are alone, you can use a gearbox jack or similar tool, or if you are on the ground, you can also use a trolley jack.

Next, remove the old pressure plate and flywheel. In order to keep the engine from rotating while removing the flywheel bolts, use a large screwdriver to insert it into the teeth and press it against the body.

Finally, I purchased a second-hand flywheel from the wrecker and processed it mechanically so that it can be used. Thoroughly clean the inside of the housing. Install a new flywheel and pressure plate, and tighten to the torque specified by the manufacturer. A bit of locknut is used on all flywheel and pressure plate bolts. Please pay attention to the use of the clutch alignment tool.

When the clutch is replaced, the gearbox modification is to a large extent a reverse process, including reconnecting all cables and wires. The clutch cable can be adjusted at the firewall by turning the two bolts. About an inch after pedaling, the clutch telemetry should find the friction point.