How To Properly Replace Clutch Plates?

Clutch plates or discs are the core friction component for power transmission in manual transmission vehicles. After prolonged use, wear and tear can lead to problems such as slipping, starting difficulties, and jerky shifting. These issues require prompt replacement. While replacing clutch plates may seem simple, it actually involves the coordinated operation of multiple components. Improper handling can compromise driving safety. This article details the steps and precautions for properly replacing clutch plates to help car owners understand the process and avoid risks.

I. Pre-Replacement Preparation: Confirming Needs and Tools

1. Determining Whether Clutch Plate Replacement is Necessary

The following symptoms may indicate excessive clutch plate wear and require replacement:

• Lack of power during startup, with engine rpm increasing but vehicle speed increasing slowly (slipping);

• Noticeable jerking and unusual noise during shifting, with incomplete disengagement;

• Clutch pedal travel becomes shallow, and it feels "soft" when pressed;

• Power transmission is interrupted when the vehicle is climbing a slope or loaded with a heavy load (commonly known as "shifting").

2. Prepare Tools and Accessories

Required Tools: Jack, hoist (or safety stand), socket wrench, torque wrench, screwdriver, circlip pliers, grease, etc.

Core Components: Clutch plate (driven plate), pressure plate, and release bearing (it is recommended to replace all three as a set, commonly known as the "clutch three-piece set");

Supplementary Materials: Transmission fluid (requires replenishment on some models), sealant (for sealing the mating surfaces).

II. Proper Steps for Replacing a Clutch Plate: From Disassembly to Installation

1. Vehicle Preparatory Procedures: Ensure Safety and Ease of Use

• Park on a flat surface, apply the parking brake, shift into neutral, turn off the engine, and disconnect the negative battery terminal (to prevent accidental tripping of the circuit);

• If the vehicle has an engine guard, remove it first to expose the connection between the transmission and the engine;

• Lift the vehicle with a jack and secure the safety stand (do not use the jack alone to support the vehicle), ensuring the vehicle is stable.

2. Disassemble the Transmission Components: Gradually Disassemble the Powertrain

Remove the Drive Shaft: Loosen the bolts connecting the drive shaft to the transmission output end and secure the drive shaft to the vehicle body (avoid bumps).

Disconnect the Transmission:

• First, remove all bolts connecting the transmission to the engine (note the bolt locations; bolt lengths may vary depending on the location).

• Secure the engine with a dedicated bracket to prevent it from sinking after the transmission is removed.

• Slowly remove the transmission rearward, taking care not to hit the flywheel and release bearing. The clutch assembly (flywheel, pressure plate, clutch plate) will now be visible.

3. Remove the Old Clutch Assembly: Check the Condition of Associated Components

• Remove the pressure plate securing bolts (loosen them evenly and diagonally to avoid deformation). Remove the pressure plate and old clutch plate.

• Remove the release bearing and release fork. Inspect the release bearing for any abnormal noise or binding (replace both if damaged).

• Clean the flywheel Surface: Sand away any oil and rust on the flywheel. Inspect the flywheel for a flat surface (if grooves or deformation are present, repair or replace the flywheel).

4. Installing the New Clutch Assembly: Precise Alignment is Key

Positioning the Clutch Plate: The new clutch plate has a directional design (usually marked "Toward Transmission" or "THIS SIDE OUT") and must be positioned correctly.

Installing the Pressure Plate: Align the new pressure plate with the locating pins. Manually tighten the mounting bolts, then use a torque wrench to tighten them diagonally (strictly follow the torque values specified in the vehicle manual, generally 25-35 N·m).

Installing the Release Bearing: Apply high-temperature grease to the contact area between the release bearing and the shift fork. Slide the release bearing onto the shift fork to ensure smooth movement.

5. Reset the Transmission and Drive Components: Ensure a secure connection

Lifting the Transmission: Slowly push the transmission back into position, ensuring the input shaft inserts smoothly into the clutch plate spline hub (if alignment is difficult, rotate the flywheel to adjust the position);

Secure the Transmission: Replace the connecting bolts according to the markings used during removal, tightening them evenly and diagonally to prevent uneven force on the mating surfaces;

Reinstalling the Drive Shaft: Reconnect the drive shaft to the transmission, tighten the securing bolts, and check for smooth rotation of the drive shaft;

Refilling the Transmission Fluid: If the transmission fluid leaked during removal, refill it according to the standard fluid type and volume (refer to the vehicle manual for the fluid type and volume).

6. Post-Operation Inspection: Verify the Replacement

• Connect the negative terminal of the battery, start the engine, and press the clutch pedal to check for normal pedal travel (usually 15-25 cm);

• Engage each gear and test for smooth shifting and any unusual noises;

• Road Test: Check for smoothness when starting at low speed and for slippage during rapid acceleration (check that the engine speed is synchronized with the vehicle speed) to ensure normal power transmission.

III. Clutch Plate Replacement Precautions: Details Determine Success

Prioritize replacing the "three-piece set": The clutch plate, pressure plate, and release bearing are linked components. Replacing the clutch plate individually may cause uneven wear on the old pressure plate, leading to unbalanced force on the new plate and shortening its service life.

Avoid component contamination: During installation, avoid touching the friction surfaces of theclutch plate and pressure plate directly with your hands (oil and dirt on your hands can cause slippage). If oil and dirt are present, wipe them clean with detergent.

Tighten bolts strictly to the required torque: Over-loosening the bolts securing the pressure plate and transmission can cause unusual noise and vibration, while over-tightening can cause bolt breakage or component deformation.

Inspect the flywheel and guide bearing: If the flywheel has cracks, grooves, or the guide bearing is stuck, repair or replace them simultaneously. Otherwise, wear on the new clutch plate will accelerate.

Professional operation recommended: Replacing the clutch plate requires disassembly of the transmission, which requires a high level of technical proficiency. Inexperienced car owners are advised to have the procedure performed by a 4S dealership or a professional repair shop to avoid secondary failures caused by improper installation.

IV. Post-Replacement Maintenance: Extending the Life of the New Clutch Plate

• Avoid sudden acceleration and heavy-load driving during the initial phase of replacement to allow the new clutch plate to fully break in with the pressure plate and flywheel (a break-in period of approximately 500 kilometers is recommended);

• Minimize the time spent in semi-engaged mode, and quickly transition to full engagement when starting to avoid prolonged slipping;

• Ensure the clutch is fully depressed when shifting to avoid forced shifts in a semi-engaged state to reduce friction plate wear;

• Regularly check the clutch pedal's free travel and promptly adjust any abnormalities to ensure complete disengagement.

Summary: Proper replacement is essential for reliable power transmission.

Replacing a clutch plate is more than a simple "replace with new" operation; it involves comprehensive maintenance of the vehicle's powertrain. From preliminary evaluation and tool preparation to disassembly, installation, and commissioning, every step requires precise execution, with particular attention to component alignment, bolt torque, and cleanliness.

For vehicle owners, understanding the replacement process can help them assess the quality of repairs. However, proper daily driving (such as avoiding frequent semi-engaged operation and coasting with the clutch depressed) is key to extending the life of the clutch plate. If power transmission problems still occur after replacement, it is necessary to promptly check the separation mechanism, hydraulic system and other related components to ensure that the vehicle's "power switch" is always sensitive and reliable.At the same time,choosing a safe and durable clutch plate is also significant,don’t choose cheap and low-quality brake parts.EV offers high-performance and safe clutch plates and related brake parts.Welcome to visit our website:https://www.evfriction.com.  You can contact us by +86-13363216781 or  jessicabrakes12@gmail.com.