Dongfeng KL truck parts Clutch master cylinder with oil reservoir assembly 1604005-TR800

Built as the core of the clutch hydraulic system, this assembly delivers efficient power transmission for smooth and precise clutch engagement/disengagement. The master cylinder’s piston uses a dual-seal design (EPDM primary seal + PTFE secondary seal) that minimizes fluid leakage and ensures a hydraulic efficiency of ≥98%, translating driver pedal force into consistent clutch actuation. The 12mm piston diameter and 80mm stroke optimize the force-to-pressure ratio, reducing pedal effort by 20% compared to standard cylinders—critical for drivers during long-haul shifts. The integrated reservoir features a sight glass and minimum/maximum level marks, allowing easy fluid level checks without disassembly. The reservoir’s vented cap maintains atmospheric pressure, preventing vacuum formation that causes clutch lag, ensuring immediate response even after prolonged idle periods

Engineered for long-term reliability in harsh truck environments, the 1604005-TR800 assembly features a rugged integrated design. The master cylinder body is precision-cast from ADC12 aluminum alloy with a 3.5mm wall thickness, achieving a tensile strength of 190MPa and resisting deformation from cab vibration (10-500Hz). The reservoir is made of impact-resistant HDPE (high-density polyethylene) that withstands accidental knocks and resists corrosion from brake fluid (DOT 3/DOT 4 compatible). A reinforced steel bracket (1.5mm thickness) integrates the cylinder and reservoir, distributing mounting stress evenly and preventing separation—an issue common with separate components. The pushrod is made of 45# carbon steel (heat-treated to HRC 35) with a chrome-plated surface, ensuring smooth movement and resisting wear over 500,000+ clutch cycles

Optimized to prevent hydraulic fluid loss and component corrosion, the assembly integrates multiple protective features. The cylinder’s internal surface is honed to a roughness of Ra 0.2μm, reducing piston seal wear and extending seal life by 40%. All fluid interfaces use O-ring seals (HNBR material) that resist swelling and degradation from brake fluid, maintaining a leak-proof seal for 200,000km. The aluminum cylinder body undergoes a hard anodizing treatment (12μm thickness) and a corrosion-resistant coating, passing 1500-hour neutral salt spray testing (ASTM B117) with no pitting. The reservoir’s HDPE material is UV-stabilized, preventing brittleness and cracking from long-term sun exposure, ensuring reliable fluid storage in all climates

This integrated clutch master cylinder assembly is designed for efficient installation and long-term cost savings for Dongfeng KL operators. Its pre-assembled design (cylinder + reservoir + bracket) allows a 2-person team to complete replacement in 1 hour—50% faster than installing separate components. The OE-compatible pushrod and mounting bracket eliminate the need for clutch system recalibration (a $300+ service for non-OE parts), minimizing downtime. By ensuring precise clutch control, it reduces clutch disc wear by 30%, extending the clutch’s service life and lowering overhaul costs (average 16-speed clutch overhaul costs $1,800+). The assembly’s 300,000km service life—three times that of aftermarket cylinders—reduces replacement frequency. Backed by a 2-year/200,000km Dongfeng warranty, it provides reliable clutch performance and predictable maintenance expenses, ensuring maximum uptime for fleet operations