SACHS 3000 990 378 Clutch Kit Instruction Manual

1. Product Overview

The SACHS 3000 990 378 Clutch Kit is engineered as a direct replacement component for specific vehicle applications. This kit provides all necessary clutch parts and components required for a complete clutch replacement, ensuring optimal performance and longevity of the vehicle's transmission system.

Key features of the SACHS clutch kit include:

• Contains all relevant components for a comprehensive clutch replacement.
• Includes special grease for assembly, designed to ensure perfect, long-term clutch functioning.
• Facilitates safe, effective, and swift clutch replacement procedures.

Figure 1: Overview of the SACHS 3000 990 378 Clutch Kit components.

2. Product Components

The SACHS 3000 990 378 Clutch Kit typically includes the following components:

• Clutch Pressure Plate
• Clutch Disc
• Release Bearing (or Concentric Slave Cylinder, CSC, in some advanced kits)
• Special Assembly Grease
• Mounting Instructions

The specific combination of components may vary. Some advanced kits may include a dual-mass flywheel (DMF) or a concentric slave cylinder (CSC).

3. Vehicle Compatibility and Application

This SACHS clutch kit is specifically designed for use as a vehicle clutch kit in accordance with the manufacturer's catalogue. It is crucial to confirm compatibility with your specific vehicle model before installation.

Compatible vehicles include, but are not limited to:

• Ford TRANSIT CONNECT V408 BOX BODY/MPV (2013 - )
• Ford MONDEO IV (BA7) (2007 - 2015)
• Ford S-MAX (WA6) (2006 - 2014)
• Ford GALAXY (WA6) (2006 - 2015)
• Ford MONDEO IV TURNIER (BA7) (2007 - 2015)
• Volvo V60 I (155) (2010 - 2018)
• Volvo V70 III (135) (2007 - 2016)
• Ford TOURNEO CONNECT / GRAND TOURNEO CONNECT V408 MPV (2013 - )
• Volvo S60 II (134) (2010 - 2019)
• Volvo S80 II SEDAN (124) (2006 - 2016)

Always refer to the vehicle's specific fitment guide or consult a qualified technician to ensure correct part application.

4. Installation Guidelines

Installation of a clutch kit requires specialized tools and technical expertise. It is strongly recommended that this product be installed by a certified automotive technician or a professional service center.

4.1 General Installation Steps (Consult Included Mounting Instructions for Details)

1. Preparation: Ensure the vehicle is safely lifted and supported. Disconnect the battery and drain transmission fluid if necessary.
2. Transmission Removal: Carefully remove the transmission from the vehicle, following manufacturer's service manual procedures.
3. Old Clutch Removal: Remove the old pressure plate, clutch disc, and release bearing from the flywheel. Inspect the flywheel for wear, cracks, or hot spots. Resurface or replace if necessary.
4. New Clutch Installation:
   • Apply the provided special assembly grease sparingly to the input shaft splines and the release bearing contact points.
   • Install the new clutch disc and pressure plate, ensuring correct alignment using a clutch alignment tool.
   • Torque the pressure plate bolts to the manufacturer's specifications.
   • Install the new release bearing (or CSC).
5. Transmission Reinstallation: Carefully reinstall the transmission, ensuring proper engagement with the clutch assembly.
6. Final Steps: Reconnect all components, refill transmission fluid, and perform a functional check.

Important: Always refer to the detailed "Mounting Instructions" included with your SACHS clutch kit and the vehicle manufacturer's service manual for precise, model-specific installation procedures and torque specifications.

5. Operation and Break-in

After installation, a proper break-in period is recommended for the new clutch to ensure optimal performance and longevity. Avoid aggressive driving, rapid acceleration, and heavy loads for the first 500-1000 miles (800-1600 km).

During normal operation, engage and disengage the clutch smoothly. Avoid riding the clutch or prolonged slipping, as this can lead to premature wear and overheating.

6. Maintenance

Clutch systems are generally designed for long service intervals. Regular maintenance of the vehicle's transmission and related components can contribute to the longevity of the clutch kit.

• Fluid Checks: For hydraulic clutch systems, regularly check the clutch fluid level and condition. Replace fluid according to vehicle manufacturer recommendations.
• Inspection: During routine vehicle servicing, have the clutch system inspected for any signs of wear, leaks, or unusual noises.
• Driving Habits: Maintain good driving habits to minimize clutch wear, such as fully depressing the clutch pedal when shifting and avoiding unnecessary clutch slipping.

7. Troubleshooting

If you experience issues with your clutch system after installation, consider the following common troubleshooting points. For complex issues, consult a professional technician.

If troubleshooting steps do not resolve the issue, seek assistance from a qualified automotive professional.

8. Specifications

The following specifications apply to the SACHS 3000 990 378 Clutch Kit:

• Manufacturer: ZF Friedrichshafen AG
• Brand: SACHS
• Model Number: 3000 990 378
• Item Weight: Approximately 13.71 pounds (6.22 kg)
• Product Dimensions: Approximately 15.76 x 11.13 x 6.25 inches (40.03 x 28.27 x 15.88 cm)
• Date First Available: November 29, 2017

Note: Specifications are subject to change without prior notice.

9. Warranty and Support

For information regarding the warranty coverage for your SACHS 3000 990 378 Clutch Kit, please refer to the warranty documentation provided with your purchase or contact the authorized SACHS distributor or retailer from whom the product was acquired.

For technical support or further assistance, please visit the official SACHS website or contact their customer service department. When contacting support, please have your product model number (3000 990 378) and purchase details readily available.

You can find more information about SACHS products at their official store: SACHS Store on Amazon.