1 - Hks

CLUTCH COMPLETE R35-GR6
INSTALLATION MANUAL
Installation must be done by a professional.
Read this manual prior to the installation.
Always have access to this manual as well as a factory service manual.
※ Make sure the vehicle is applicable to this kit.
NAME OF PRODUCT
PART NUMBER
APPLICATION
ENGINE
YEAR
REMARKS
CLUTCH COMPLETE R35-GR6
27003-AN015
NISSAN GT-R R35
VR38DETT
2007/11 The following items are required in order to install this product:
※ HKS DCT fluid
Select from the following:
・ DCTF-1 52002-AK001 (20L)
・ DCTF-2 52002-AK002 (20L)
※ Liquid Gasket: TB1217 or an equivalent
※ Silicone Grease: TB185 or an equivalent
REVISION OF MANUAL
Rev. Number
Date
3-3.01
2013/06
Details
st
1 Edition
Published in June, 2013 by HKS Co., Ltd. (Unauthorized reproduction is strictly prohibited.)
INDEX
NOTICE / ATTENTION / SAFETY PRECAUTIONS···············································································2
PARTS LIST ············································································································································3
1. REMOVAL OF FACTORY PARTS·······································································································4
2. INSTALLATION OF KIT PARTS···········································································································6
NOTICE
This manual assumes that you have and know how to use the tools and equipment necessary to safely perform service
operations on your vehicle. This manual assumes that you are familiar with typical automotive systems and basic service
and repair procedures. Do not attempt to carry out the operations shown in this manual unless these assumptions are
correct. Always have access to a factory service manual. To avoid injury, follow the safety precautions contained in the
factory service manual.
ATTENTION
● This manual indicates items you need to pay attention to in order to install this product safely and lists precautions to
avoid any possible damage and/or accidents.
● This product is an automobile part. Do not use for any other purposes.
● HKS will not be responsible for any damage caused by incorrect installation and/or use, or use after modification
and/or dismantling of this product.
● This product was designed for installation on a specific factory vehicle.
● The specifications of this product are subject to change without notice.
● The instructions are subject to change without notice. Make sure to refer to the most recent instructions.
-2-
PARTS LIST
NO.
DESCRIPTION
QT
1
Dual Wet Clutch Assembly
1
2
Retaining Ring
1
3
Instruction Manual
1
4
Installation Manual
1
-3-
IMAGE
REMARKS
１．REMOVAL OF FACTORY PARTS
Disconnect the negative cable from the battery and prepare required items prior to the installation.
Use this instruction manual and the manufacture’s service manual as a reference.
(1) Remove the transmission from the vehicle referring to the factory service manual.
＊ The following installation process must be done in an immaculately clean room.
＊ Prevent a foreign object and/or dust from entering into inside of the transmission to avoid malfunction.
(2) Remove the oil pan from the transmission. (Dia.1-2-1)
Oil Pan
1-2-1
(3) Remove the oil strainer. (Dia.1-3-1)
Oil Strainer
1-3-1
(4) Disconnect the connector and remove the fixture bolt shown
in the diagram 1-4-1.
Fixture Bolt
Connector
1-4-1
(5) Remove the fixture bolts (20pcs) from the front housing
assembly; then remove the front housing assembly from the
transmission. (Dia.1-5-1)
Front Housing Assembly
Fixture Bolts
1-5-1
-4-
(6) Remove 4 bolts shown in the diagram 1-6-1; then remove the
hydraulic module (FCM) from the front housing assembly.
(Dia.1-6-1)
Bolts
Hydraulic Module
＊Remove only bolts specified in the diagram 1-6-1. Failure to
do so may cause malfunction of the transmission.
(7) Check the following parts of the removed hydraulic module: oil
pump, filter, sealing, etc.
1-6-1
(8) Remove the circlip shown in the diagram 1-8-1; then remove the
clutch pack assembly.
Clutch Pack Assembly
Circlip
(9) Remove the gasket between the front housing and the
matching surface of the transmission’s main part. Remove
all debris and contamination from the area the gasket was
removed to prevent malfunction.
(10) Make sure 2 bearings and 4 seal rings are aligned with the
groove properly. Reinstall them if necessary. If the
bearing and seal rings are not properly installed, it may
cause malfunction. (Dia.1-10-1)
1-8
Seal Rings
Bearings
1-10-1
(11) Make sure 2 O-rings shown in the diagram are properly
installed. If the O-rings are not properly installed, it may
cause malfunction. (Dia.1-11-1)
O-rings
1-11-1
-5-
２．INSTALLATION OF KIT PARTS
(1) Install P1 to the front housing. (Dia.2-1-1)
P1
＊When installing P1, rotate P1 to the right and left so the spline
engages properly. Do not force the spline to engage to prevent
damage to the sealing ring and/or bearing. If P1 cannot be
installed properly, check the sealing ring and bearing. (Dia.
1-10-1)
2-1-1
(2) Secure P1 to the front housing using P2. (Dia.2-2-1)
P2
＊Make sure P2 is aligned with the groove properly to prevent
damage to the transmission.
2-2-1
(3) Apply silicone grease to 2 O-rings and 5 pipe seals as shown in
the diagram 2-3-1.
Pipe Seals
Silicone Grease ThreeBond TB1855
O-rings
2-3-1
(4) Reinstall the hydraulic module to the front housing reusing the
factory bolts. (Dia.2-4-1)
Factory Bolts
Tightening Torque (N･m) T=9.2±0.9
2-4-1
-6-
(5) Make sure the thrust washer is installed to the output shaft.
(Dia.2-5-1)
Thrust Washer
Output Shaft
2-5-1
(6) Remove oil from the matching surface of the transmission.
Apply liquid gasket continuously to the matching surface as
shown in the diagram 2-6-1.
Liquid Gasket
Liquid Gasket ThreeBond TB1217 (Gray)
NOTE
Apply liquid gasket to the center of the flange and inside the
threaded hole (approximately the diameter of 3mm).
2-6-1
(7) Remove oil from the matching surface of the front housing.
Reinstall the front housing to the transmission reusing the
factory bolts. Make sure the connector comes to the position
as shown in the diagram 2-7-1. (Dia.1-5-1, 2-7-1)
Connector
Tightening Torque N･m T=22±2.2
2-7-1
(8) Reinstall all removed factory parts.
(9) Perform the clutch assembly process shown in the assembly manual in accordance with the factory service manual.
-7-
Clutch Complete R35-GR6
Assembly Manual
NAME OF PRODUCT
PART NUMBER
APPLICATION
ENGINE
YEAR
REMARKS
CLUTCH COMPLETE R35-GR6
27003-AN015
NISSAN GT-R R35
VR38DETT
2007/11 The following items are required in order to install this product:
※ HKS DCT fluid
Select from the following:
・ DCTF-1 52002-AK001 (20L)
・ DCTF-2 52002-AK002 (20L)
※ Thread Locking Fluid: TB1324N or an equivalent
※ Silicone Grease: TB185 or an equivalent
REVISION OF MANUAL
Rev. Number
Date
3-3.01
2013/06
Details
st
1 Edition
Published in June, 2013 by HKS Co., Ltd. (Unauthorized reproduction is strictly prohibited.)
-8-
INDEX
NOTICE / ATTENTION / SAFETY PRECAUTIONS···············································································9
PARTS LIST ············································································································································10
1. CLUTCH ASSEMBLY ··························································································································12
2. DISASSEMBLY PROCEDURE ············································································································21
NOTICE
This manual assumes that you have and know how to use the tools and equipment necessary to safely perform service
operations on your vehicle. This manual assumes that you are familiar with typical automotive systems and basic service
and repair procedures. Do not attempt to carry out the operations shown in this manual unless these assumptions are
correct. Always have access to a factory service manual. To avoid injury, follow the safety precautions contained in the
factory service manual.
ATTENTION
● This manual indicates items you need to pay attention to in order to install this product safely and lists precautions to
avoid any possible damage and/or accidents.
● This product is an automobile part. Do not use for any other purposes.
● HKS will not be responsible for any damage caused by incorrect installation and/or use, or use after modification
and/or dismantling of this product.
● This product was designed for installation on a specific factory vehicle.
● The specifications of this product are subject to change without notice.
● The instructions are subject to change without notice. Make sure to refer to the most recent instructions.
-9-
PARTS LIST
NO.
DESCRIPTION
QT
IMAGE
REMARKS
1
Hub Assembly Drive DCT
1
2
Plate Retaining DCT Drive Hub
1
3
Retaining Ring
1
BR32
4
Seal Outer DCT Piston
2
Large w=2.6
5
Seal Inner DCT Piston
2
Small w=1.8
6
Piston DCT Odd Number
1
7
Spring Return DCT Piston
24
8
Seal Outer DCT Balance Piston
2
Middle w=3.5
9
Retainer Piston DCT Odd Number
1
D=111d=65 T=9.0
10
Retaining Ring
2
WR65
11
Cage Assembly Drive DCT
1
12
Disk Clutch Assembly Driven DCT
16
13
Plate Clutch Drive DCT
18
14
Plate Retaining DCT Outer Cage
1
15
Retaining Ring
1
BR173
16
Bolt Low Head Cap Hexagon
24
M5 L8
17
Retainer Bearing DCT Cover
1
18
Bearing DCT
1
19
Hub Assembly Driven Odd Number
1
20
Bearing Barrel
1
- 10 -
6815
AXK4565
PARTS LIST
NO.
DESCRIPTION
QT
IMAGE
REMARKS
21
Hub Assembly Driven Even Number
1
22
Gear Drive PTO DCT
1
23
Cover DCT
1
24
Bearing DCT
1
6910
25
Plate Cover DCT
2
Flange Type
26
Plate Cover DCT
2
Spline Type
27
Bolt Torx Socket
24
M5 L12
28
Piston DCT Even Number
1
29
Retainer Piston DCT Even Number
1
30
Cage Outer DCT
1
31
Actuator DCT Even Number
12
32
Retaining Ring
1
- 11 -
D=111d=65 T=12.5
BR183
1．CLUTCH ASSEMBLY
＊ The following installation process must be done in an immaculately clean room.
＊ Prevent a foreign object and/or dust from entering into inside of the clutch pack to avoid malfunction.
(1) Install P2 to P1 using P3. The chamfered side of P2 must be faced downward. (Dia.1-1-1, 1-1-2)
P1
P3
P3
P2
P2
Chamfered side
1-1-1
P1
1-1-2
(2) Apply silicone grease to P4; then install P4 to P1. (Dia.1-2-1)
＊ Make sure P4 Seal is not twisted.
P4
Silicone Grease ThreeBond TB1855
1-2-1
(3) Apply silicone grease to P5; then install P5 to P1. (Dia.1-3-1)
＊ Make sure P5 Seal is not twisted.
P5
Silicone Grease ThreeBond TB1855
1-3-1
(4) Apply a thin coat of DCTF to the sliding portion of P6; then install
P6 to P1.
Make sure the gap indicated by arrows in the diagram 1-4-1 is
equal. (Dia.1-4-1)
P6
DCTF HKS DCTF-2
NOTE
Apply just a drop of DCTF to one part of the sliding portion
with the finger. Make sure to clean the finger before
applying DCTF.
- 12 -
1-4-1
(5) Install 12 pieces of P7 to P6. (Dia.1-5-1)
P7
1-5-1
(6) Apply silicone grease to P8; then install P8 to P9. (Dia.1-6-1)
＊ Make sure P8 Seal is not twisted.
P9
Silicone Grease ThreeBond TB1855
P8
1-6-1
(7) Apply a thin coat of DCTF to the sliding portion of P9; then install
P9 to the press machine, and secure P9 with P10. (Dia.1-7-1,
1-7-2, 1-7-3)
DCTF HKS DCTF-2
NOTE
Apply just a drop of DCTF to one part of the sliding portion
with the finger. Make sure clean the finger before applying
DCTF.
1-7-1
＊Load must be less than 2kn.
P9
P9
P10
P10
1-7-3
1-7-2
- 13 -
(8) Place P11 higher frame side upward; then alternately install P13
and P12. (Dia.1-8-1)
P11
P13
*8-disk specification: P13 (1.3mm) x 9, P12 x 8
P12
＊ This procedure is for a temporary assembly. Adjustment will be
done later after measurement.
1-8-1
(9) Install P15 to P11. If P15 does not fit, grind the surface of P15.
Make sure the gap between P15 and P11 does not become
wider than 0.04mm. (Dia.1-9-1)
P11
＊The thickness of P15 must be more than 2.43mm.
(10) Remove P15 from P11.
P15
(11) Install P14 to P11. Place the flat surface of P14 downward
when installing P14 to P11. (Dia.1-11-1)
1-9-1
P14
P11
1-11-1
(12) Install P15 to P11. (Dia.1-12-1)
P15
＊Press P15 with a flathead screwdriver till P15 fits the groove of P11
securely.
P11
- 14 -
1-12-1
(13) Temporarily install P1 to P11 using P16 (18 pieces).
(Dia.1-13-1)
P1
P16
NOTE
For temporally assembly, use only 6 pieces of P16 at intervals
of 60 degree.
P11
1-13-1
(14) Set up the pressure inspection tool. Send 0.7 – 1.0Mpa air to
the odd-numbered pistons; then measure the piston stroke
(movement of P6). (Dia.1-14-1)
Standard Stroke (mm) 2.45 – 2.80
P6
＊If the stroke is out of the standard value, change the thickness of
P13; then measure the stroke again.
When changing to thinner plate, replace the bottom plate.
When changing to thicker plate, replace the top plate.
1-14-1
(15) After adjustment is completed, apply thread locking fluid to the
thread; then install all 18 pieces of P16. Tighten them
securely.
Tightening Torque N･m 5.4±0.27
P18
Thread Locking Fluid ThreeBond TB1324N or equivalent
P17
(16) Press-fit P17 to P18. (Dia.1-16-1)
＊Make sure to press P17 straight.
＊Make sure not ot press P18’s outer race.
＊Press-fitting load must be less than 10kN.
＊Make sure P18 rotates smoothly after press-fitting.
(17) Install P18 to P19. When installing P18, lightly and equally hit
the outer periphery of P18 with a plastic hammer’s grip to
insert P18. (Dia.1-17-1)
＊Make sure P18 rotates smoothly after installing.
1-16-1
P19
P18
(18) Pour a drop of DCTF to 4 points of P18 at intervals of 90
degree.
1-17-1
DCTF HKS DCTF-2
- 15 -
(19)
Install P19 to P1.
(Dia.1-19-1)
Make sure P19 engages all P12.
P19
1-19-1
(20) Install P20 to P19. Pour a drop of DCTF to 2 points of P20 at
intervals of 180 degree. (Dia.1-20-1)
P20
DCTF HKS DCTF-2
1-20-1
(21) Install P21 to P22. (Dia.1-21-1)
P21
1-21-1
(22) Install P13 and P12 alternately to P11. (Dia.1-22-1)
*8-disk specification: P13 (1.3mm) x 9, P12 x 8
＊ This procedure is for a temporary assembly. Adjustment will be
done later after measurement.
P11
- 16 -
1-22-1
(23) Press-fit P24 to P22. (Dia.1-23-1)
＊Make sure to press P24 straight.
＊Make sure not to press P24’s inner race.
＊Press-fitting load must be less than 10kN.
＊Make sure P24 rotates smoothly after press-fitting.
P24
P22
1-23-1
(24) Apply thread locking fluid to the thread; then install P23 to P22
using 6 pieces of P16. (Dia.1-24-1)
P22
P16
Tightening Torque N･m 5.4±0.27
Thread Locking Fluid ThreeBond TB1324N or equivalent
P23
(25) Alternately install 2 piece of P25 and 2 pieces of P26 to P11.
P25
(Dia.1-25-1)
1-24-1
P26
P25
P26
1-25-1
(26) Temporarily install P23 to P25 and P26 using 12 pieces of
P27. (Dia.1-26-1)
P27
P23
1-26-1
- 17 -
(27) Apply silicone grease to P5; then install P5 to P1. (Dia.1-27-1)
＊ Make sure P5 Seal is not twisted. (Dia.1-27-2)
Silicone Grease ThreeBond TB1855
P1
P5
P5
1-27-2
1-27-1
(28) Apply silicone grease to P4; then install P4 to P28.
(Dia.1-28-1)
＊ Make sure P4 Seal is not twisted.
P28
P4
Silicone Grease ThreeBond TB1855
1-28-1
(29) Apply a thin coat of DCTF to the sliding portion of P28; then
install P6 to P1. (Dia.1-29-1)
P28
DCTF HKS DCTF-2
NOTE
Apply just a drop of DCTF to one part of the sliding portion
with the finger. Make sure to clean the finger before
applying DCTF.
1-29-1
(30) Install 12 pieces of P7 to P28 as shown in the diagram
1-30-1.
P28
P7
1-30-1
- 18 -
(31) Apply silicone grease to P8; then install P4 to P29.
(Dia.1-31-1)
＊ Make sure P8 Seal is not twisted.
P29
Silicone Grease ThreeBond TB1855
P8
1-31-1
(32) Apply a thin coat of DCTF to the sliding portion of P29; then
install P29 to the press machine, and secure P29 with P10.
(Dia.1-32-1, 1-32-2, 1-32-3)
DCTF HKS DCTF-2
NOTE
Apply just a drop of DCTF to the sliding portion with the
finger. Make sure to clean the finger before applying
DCTF.
1-32-1
＊Load must be less than 2kn.
P29
P10
P29
P10
1-32-2
(33) Install 12 pieces of P31 to P30 using P27. (Dia.1-33-1)
1-32-3
P27
Tightening Torque N･m 5.4±0.27
P31
Thread Locking Fluid ThreeBond TB1324N or equivalent
P30
- 19 -
1-33-1
(34) Install P32 to P28. (Dia.1-34-1)
P28
P32
1-34-1
(35) Install P30 to P28 as squeezing P32. (Dia1-35-1)
P28
P30
(36) Set up the pressure inspection tool. Send 0.7 - 1.0Mpa air to
the even-numbered pistons; then measure the piston stroke
(movement of P28). (Dia.1-36-1)
1-35-1
P28
Standard Stroke (mm) 2.45 – 2.80
＊If the stroke is out of the standard value, change the thickness of
P13 referring to the disassembly procedure on the next page;
then measure the stroke again.
1-36-1
When changing to thinner plate, replace the bottom plate.
When changing to thicker plate, replace the top plate.
(37) Send 0.7 - 1.0 Mpa factory air to both odd and even-numbered
pistons to check for air leakage.
P27
Standard
Pistons do not move more than 5 seconds after closing the
cock and shutting off the original pressure.
(38) After adjustment is completed, apply thread locking fluid to the
thread; then tighten securely 12 pieces of bolts inside P27.
1-38-1
Tightening Torque N･m 5.4±0.27
Thread Locking Fluid ThreeBond TB1324N or equivalent
- 20 -
2．DISASSEMBLY PROCEDURE (Summary Abstract)
(1) Set the clutch main unit to the pressure inspection tool.
(Dia.2-1-1)
(2) Insert a M3 bolt or small bolt to the service screw hole of P30,
and tighten them. (Dia.2-1-1)
2-1-1
(3) Make sure the P32 is come off the groove using a thickness
gauge. When using a thickness gauge, make sure the gauge
can rotate without touching the M3 screw head. (Dia.2-3-1)
(4) Insert a thickness gauge to the gap of P32.
2-3-1
(5) Gradually apply the factory pressure to the even-numbered
pistons so P30 is separated from the main unit. If P30 cannot be
separated, adjust the tightness of the M3 screw. (Dia.2-5-1)
(6) Disassemble the remaining parts using the opposite of the
assembly procedure.
NOTE
It is not necessary to disassemble the press-fit parts of the bearing.
2-5-1
NOTE
When removing P23 from the main unit, remove only the connecting
bolt between P23 and P25 without removing P26. (Dia.A-1)
A-1
- 21 -