Assembly and installation of the ZIL-5301 clutch

Assembling the pressure plate should be done in the reverse order of disassembly, on an auxiliary flywheel used as a device, placing a steel disc with a diameter of 300 mm and a thickness of 9.8 mm under the clutch pressure plate to adjust the position of the levers

Install the flywheel on a bench, place a steel disk on it and install the clutch pressure plate on it (see Figure 1).

Assemble the needle bearings by inserting a technological ball made of soft oil-resistant rubber with a diameter of 8.8-9.5 mm into the lever hole, then insert nineteen needle rollers lubricated with Litol-24 grease between the rubber ball and the wall of the lever hole. .

In a similar way, insert nineteen needle rollers into the second hole of the lever.

Align the hole in the support fork with the hole in the lever; in this case, the spherical protrusion of the inner end of the lever should be directed in the same direction as the threaded rod at the fork.

Insert a short finger into the aligned holes, pushing out the rubber ball.

Splint the finger.

Following the markings made during disassembly, install the lever in the groove between the pressure plate lugs, aligning the holes in the lever and the lugs.

Insert a long finger (see Fig. 2, a) into the aligned holes, pushing out the rubber ball.

Splint the finger.

If there are no rubber balls, needle rollers can be assembled by applying a layer of lubricant to the surface of the holes, to which the rollers seem to be glued.

Moreover, needle rollers must be placed in the second hole after assembling the lever with the fork (see Fig. 2,b).

Install the remaining levers in the same way. In this case, the heads of the fingers should take a position in the direction of rotation.

Put heat-insulating washers on the protrusions of the pressure disk (Fig. → 3, a), and put pressure springs on the washers (see Fig. 1, e).

Aligning the marks on the casing and disk made during disassembly to maintain balance, install the clutch casing on the springs (see Fig. 1,e), directing them to the protrusions on the inner surface of the casing; in this case, the threaded ends of the support forks must fit into the holes of the casing.

To prevent the threaded rods of the lever forks from jumping out of the casing holes, it is advisable to put extensions on them in the form of thin-walled tubes

Align the holes on the casing support legs with the threaded holes of the auxiliary flywheel, install extended centering bolts and tighten the casing legs to the flywheel, tightening all the bolts gradually and sequentially.

Install the bushings into the shaped holes of the paired tangential spring plates, screw in the bolts securing these plates, tighten the bolts (the tightening torque should be 10-15 Nm), then lock them by bending the thin shoulder of the bushing onto the edge of the bolt head.

Screw the adjusting nuts onto the threaded rods of the forks until the end of the nut coincides with the end of the threaded rod of the fork.

Install the support clamping plates and locking plates on the adjusting nuts, screw in the bolts securing these plates and pre-tighten them until the ends of the support plates touch the casing.

Adjusting the clutch release levers

Without removing the assembled clutch pressure plate from the auxiliary flywheel, used as a device, it is necessary to adjust the position of the ends of the levers relative to the working surface of the pressure plate.

By rotating the adjusting nuts with a wrench (Fig. 4), set all the levers in such a position that the distance from the working surface of the pressure plate to the tops of the spherical protrusions at the inner ends of the levers is within 39.7-40.7 mm. In this case, the ends of the levers must lie in the same plane, parallel to the working surface of the pressure plate with an accuracy of 0.5 mm.

Measurements should be made using a height gauge ShR-250 GOST 164-73, resting it on a steel disk that replaces the driven disk. Rice. 4.

Adjusting and checking the location of the clutch release levers using a disc and height gauge

Having finished adjusting the clutch, you need to tighten the bolts securing the support plates (tightening torque 10-15 Nm), lock the bolts by bending one tendril of the locking plate along the edge of the bolt and lock the threaded connection of the adjusting nut with the threaded end of the fork (tighten at one point).

Unscrew the bolts securing the casing to the auxiliary flywheel and remove the disk assembly with the casing. In this case, all bolts should be unscrewed gradually and sequentially to avoid deformation of the clutch casing.

Installing the clutch on the engine

Place the driven disk, pointing the protruding part of the disk hub towards the flywheel, install the pressure disk assembly with the casing on the flywheel, aligning the existing marks on the casing and the flywheel, secure the casing to the flywheel, first tightening several mounting bolts by hand.

Center the driven disk relative to the flywheel using a special splined mandrel or an auxiliary transmission input shaft by inserting it into the splined hole of the driven disk hub and into the crankshaft flange bearing.

Screw in the missing mounting bolts and finally tighten the casing to the flywheel, first placing spring washers under the bolt heads.

All bolts must be tightened gradually and sequentially with a torque of 28-36 Nm.

Remove the auxiliary shaft from the spline hole.

Install the clutch release fork, the fork flange and secure it with bolts and spring washers.

Then put the fork lever on the small slots, aligning the marks on the lever and the end of the fork, insert and tighten the lever locking screw with the spring washer.

Some mechanics, due to inexperience, install the driven disk on the wrong side, although in principle it can be installed on the wrong side. But in this case, the disk will quickly fail.

Look in section and place it as in the picture.