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Objectives
Describe the various clutch components and their functions. Name and explain the advantages of the different types of pressure plate assemblies. List the safety precautions that should be followed during clutch servicing.
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Objectives
Explain how to perform basic clutch maintenance. Name the six most common problems that occur with clutches. Explain the basics of servicing a clutch assembly.
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Drive Trains
Rear-Wheel Drive Vehicle
Automotive Clutch
Used to connect and disconnect the engine and manual transmission or transaxle Allows the driver to control power flow between the engine and transmission or transaxle
Vehicles with manual transmissions require a clutch Power flow from one unit to another can be controlled with a drive disc and a driven disc
Clutch Theory
Clutch is disengaged
Clutch is engaged
Introduction Clutches In order to change gear, the drive between the engine and the gearbox must be temporarily disconnected. The vehicle clutch enables the driver to do this.
A clutch is a component that is designed to connect together two rotating shafts. Clutches can be classified as one of two types - positive engagement (dog clutch) or gradual engagement (friction clutch). Positive engagement clutches normally use teeth in order to provide a positive connection, whereas gradual engagement clutches use friction
The clutch is situated between the engine and the transmission gearbox. In this example depressing the clutch pedal will engage and disengage the engine from the transmission. The clutch is designed to gradually and smoothly transmit power from the engine to the transmission to enable a vehicle to start off under full control. Note: The ability of a clutch to transmit torque (clutch capacity) is normally between 1.2 and 1.4 times the maximum torque of the engine. Commercial vehicles usually have a capacity between 1.5 and 2.5. If the clutch is too light, slipping will take place and lead to premature failure. Too large a clutch will tend to cause the engine to stall and is inefficient
Simplified Clutch
Clutch Components
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Components:
pilot bearing flywheel clutch disc pressure plate release bearing clutch housing (bell housing) clutch release mechanisms clutch start switch
Clutch Components
Clutch housing
Connects engine and transmission and houses the clutch assembly.
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Clutch Components
Flywheel
Acts as balancer for the engine. Adds inertia to the rotating crankshaft. Provides a surface for the clutch to contact.
Some flywheel have Ring gear for starter engagement Some vehicles have dual mass flywheel
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Flywheel
A mounting place for the clutch The pressure plate bolts to the flywheel face Flywheel face is precision machined to a smooth surface, where it contacts the clutch disc Normally made of iron for good wear and heat dissipation
Clutch Components
Clutch (input) shaft
Projects from the front of the transmission. Usually has a pilot that rides in a bearing or bushing in the end of the crankshaft. The clutch disc is splined to the clutch shaft. When engaged, the clutch disc drives the input shaft.
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Clutch Disc
Consists of a splined metal hub and a round metal plate covered with friction material (lining) Splined to the transmission input shaft Disc is free to slide back and forth on the shaft
Clutch Components
Clutch disc
Is covered with friction material. Transmits power from the engine crankshaft to the transmission input shaft. Torsional coil springs or rubber grommets allow the disc to rotate slightly in relation to the pressure plate while they absorb the torque forces.
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Clutch Components
Clutch disc
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Clutch Disc
The central hub is splined to fit on the gearbox input shaft and is free to rotate a limited distance in relation to the friction faces. This movement is governed by torsion dampers made usually from coil springs or rubber inserts and reduces initial shock at power take up.
There is a tendency for the disc to stick to the flywheel or pressure plate when released in much the same way that two sheets of glass are hard to separate due to air pressure. Grooves in the friction faces help air to enter the gap forming when the pressure plate moves away from the disc.
Clutch Components
Clutch disc (cont)
The clutch facings are riveted to wave springs, or cushioning springs, which cause the contact pressure on the facings to rise gradually when the clutch is engaged. These springs eliminate chatter by dampening the clutch engagement.
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Pressure Plate
Spring loaded device Locks or unlocks the clutch disc and the flywheel Clutch disc fits between the flywheel and pressure plate Two basic types:
coil spring diaphragm spring
Clutch Components
Diaphragm Spring Coil Spring
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Components
Small coil springs
clamp clutch disc between face and flywheel
Face
large ring that contacts the clutch disc
Release levers
allow the release bearing to move the face hinged inside the pressure plate
Clutch Components
Release bearing
Is operated by the clutch linkage. Presses against the pressure plate to release the clutch.
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Release Bearing
Usually a ball bearing and collar assembly that reduces friction between the pressure plate levers and the clutch fork A few imported vehicles use a graphite bearing
ring shaped block of graphite presses on a smooth, flat plate on the clutch release levers
Clutch Components
Pilot bearings
The purpose of the pilot bushing or bearing is to support the outer end of the transmissions input shaft. Allows the input shaft to rotate in the crankshaft.
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Pilot Bearing
Made of a solid bronze bushing, roller or ball bearing Prevents the transmission shaft and clutch disc from wobbling when the clutch is released
Clutch Linkage
Clutch linkage transfers the clutch pedal movement to the release bearing.
Mechanical clutch linkage uses shafts, levers, or a cable.
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Clutch Linkage
Hydraulic clutch linkage consists of a master cylinder, hydraulic tubing, and a slave cylinder.
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Clutch Cylinder
Produces hydraulic pressure for the system Mounted to the firewall or cowl Push rod links the clutch pedal and the cylinder piston Most systems use brake fluid
Clutch Cylinder
Slave Cylinder
Uses hydraulic pressure to cause clutch fork movement
Lined Discs
A typical clutch assembly contains the apply piston, piston return springs, and the clutch plates.
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Dragging clutch
Is usually caused by linkage problems, incorrect pedal adjustments, or defective clutch assembly.
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Binding clutch
Is usually caused by binding linkage or cables, defective clutch assembly, or improper installation.
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Flywheel service
Visually inspect for hot spots, grooves, scoring and cracks Check with dial indicator for run out and crank end play Most flywheels can (should) be resurfaced
Must remove dowel pins
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Hard pedal
Is commonly caused by binding linkage or swollen cups in the master or slave cylinder.
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Pilot servicing
Should always be changed with clutch Can be isolated by applying clutch in gear Special pullers may be used for removal
Can be removed with grease