CLUTCH INSTALLATION TIPS

From ZF Aftermarket

ZF Aftermarket has shared the following advice for workshops, to help avoid errors when conducting clutch disc installations.
Before replacing the entire unit, ZF Aftermarket advises workshops to always check the surrounding components in the event of clutch malfunctions, including the clutch actuation and the seals of the engine, flywheel, and transmission.

Examining the clutch disc before assembly
The clutch disc, also known as the drive plate, is subjected to the greatest load, because the clutch’s mode of operation results in mechanical abrasion. For this reason, the clutch disc must have high wear and temperature resistance.
Before installation, workshops should double check the condition of the clutch packaging and the new part, as they could have been damaged during transport, or because of improper handling.
To be completely certain of the condition of the part, workshops should make sure that the lateral run-out of the disc does not exceed the limit value of 0.5 millimeters. If it does, this can be corrected using a straightening fork.

Pay attention to the installation position and precisely center the clutch disc
When installing the clutch disc, make sure it is in the right position. Incorrect installation can result in damage to the disc itself, its hub spline, release lever, or even to the transmission.
Fitting instructions can usually be found on the component side. If no indications can be found, compare the new part with the old one before installation.
The new clutch disc must be precisely centered to prevent damage to the hub spline. There is a tolerance range of only a few hundredths of a millimeter between the transmission input shaft and the hub spline.
Even small inaccuracies during insertion of the transmission input shaft can prevent the mobility later required for disengaging the clutch. The hub spline must slide onto the transmission shaft without resistance.
ZF Aftermarket recommends greasing the hub spline with Sachs high-performance grease. It says its viscous consistency and temperature resistance means it adheres to the spline during operation without spreading.
In order to prevent clutch shudder when the clutch is later disengaged, excess grease must always be removed, and care must be taken to keep the clutch linings absolutely clean.

Sachs Clutches
ZF Aftermarket offers clutches, dual-mass flywheels, and clutch actuation systems under its product brand Sachs, as well as clutch kits that include all the relevant components needed for a clutch repair.

For more information, visit www.zf.com/sachs