CLUTCH SYSTEM

Purpose: To transfer power from engine to flywheel. Basically clutches connect and disconnect two
rotating shafts.
Clutch system existed either in manual transmissions, automatic transmission and even semiautomatic transmission.
Automatic transmissions: one type of motor vehicle transmission that can automatically
change gear ratios as the vehicle moves, freeing the driver from having to shift gears
manually.
Manual transmissions: used a mechanical clutch to transmit torque, rather than a torque
converter, thus avoiding the primary source of loss in an automatic transmission. Driver need
to instantly shift gears and press clutch pedal manually.
Semi-automatic transmissions: An advance system which still uses a clutch to perform the
gear shift instead of the torque converter. Unlike manual transmissions, the computer does all
of the clutch disengaging, gear shifting, and clutch engaging.

Basic component inside clutch system:

Pressure plate

Pressure plate is cast iron plate.

Clutch disc wedged between pressure plate and flywheel.
Space between plate and flywheel is less than thickness of clutch disc.
Engine and transmission are physically connected when clutch pedal released.

Release Lever

Release levers attached to cover assembly at pivot points.

Pushing clutch pedal moves pivot lever, this will pulls pressure plate away from flywheel.

Pilot Bearing or Bushing

Engine side of transmission input shaft.

Release Bearing

Release bearing allow pressure plate release mechanism to operate as crankshaft rotates.
Slides on the front transmission bearing retainer.
Self-centering release bearings do not use pilot bearing in the crankshaft.
Without pilot bearing, transmission input shaft incorrectly aligned with rear of crankshaft.

Clutch Fork

Release bearing hub has provision to attach it to the clutch fork.

Clutch fork fits between release bearing and clutch cable or linkage.
Clutch fork has pivot shaft or pivot ball or raised area in the bell housing off which it pivots.

Type of clutch linkage:

Clutch cable:
Newer cars use less expensive cable.
Adjustment remains the same as the engine moves.
Develop friction and wear with repeated use.
Linkage can push on clutch arm. ( Cable can only pull on it.)
Pivot point of fork must be on the outside of the input shaft, away from the cable end.
Hydraulic clutch:
Input piston is in the master cylinder, connected to the clutch pedal.
Output piston located in the reaction or actuator cylinder. (Attached to release lever at the
clutch).
Difference between clutch master cylinder and brake cylinder:- Clutch master cylinder does
not have residual check valve.

Electronically controlled clutch:

This system is hydraulically operated clutch that is electrically controlled and no
clutch pedal.
Sensor send information from throttle, engine, clutch and transmission to an
electronic control module( ECM).

When driver moves the gear shift lever, ECM then signals the hydraulic power
system. It controls the fluid pressure in hydraulic cylinder to engage or disengage the
clutch.

Wet VS Dry
Clutch exist either in wet and dry condition. But which offer better performance? Youll be the judge.
Wet: Wet clutches is immersed in a cooling lubricating fluid that also keeps surfaces clean and
provides smoother performance and longer life. However, it tends to lose some energy to the liquid.
Wet clutches tend to have multiple plates.
Dry: Dry clutch does not immersed or bathed in liquid and literally dry. Dry clutches tend to be
bigger in diameter and have one plate and run in air. It tends to be a bit grabby at times especially
when they are hot.

TYPES OF CLUTCH
1. Coil spring clutch
2. Diaphragm-spring clutch
3. Double disc clutch

COIL SPRING CLUTCH

What is it?

Usually it only has one clutch plate which the coating is laid out for dry friction and higher friction
value. The clutch plate is a two-piece disk about 8 inch about 20cm in diameter. In the center of the
plate is a hole with splines (similar to gear teeth) which is the same as the splines of the input shaft of
the transmission. Both side of the plate are covered with friction material which is high-friction, lowwearing, heat resistant material which is attached by rivet and bonding.

Which vehicle uses this?

A manual transmission car.
How it work?
When the pedal clutch is pressed, either a release bearing under hydraulic pressure or operating by a
cable, presses down the center of clutch cover and this will force away the pressure plate from the
clutch plate. This action allows the clutch plate to remain stationary between the revolving of
flywheel and clutch cover or as we all know as free position or in neutral position. Gears may
now be selected, and slowing releasing the clutch pedal will gradually clamps the clutch plate to the
flywheel and this will allow a direct drive from the crankshaft to the transmission.

Diaphragm-spring clutch.
What is it?

One that uses a single diaphragm spring, rather than several coil springs, to help release the clutch
disk. Diaphragm spring replaces release levers and coil springs. Friction disk clutches generally are
classified as push type or pull type depending on the location of the pressure plate fulcrum points.

There are two type of diaphragm- spring clutch:

1. Push action release mechanism
In the push type clutch, the release bearing is pushed into the clutch disengaging the
vehicle drive. In this instance, the release bearing can be known as the thrust bearing.
2. Pull action release mechanism
In the pull type clutch, the action of pressing the pedal pulls the release bearing,
pulling on the diaphragm spring and disengaging the vehicle drive.

Advantages of diaphragm-spring clutch:

Requires lower pedal operating pressure.

Takes up less space.
Spring pressure becomes greater as disc wears.
Well balanced.
Dual mass flywheel reduces noise and vibration to allow smoother gear shifting.

Advantages of coil spring vs diaphragm spring

More coil springs can be installed.

Centrifugal force applies clutch more tightly

Disadvantages of coil spring

More pedal pressure required.

Clutch applied less heavily as disc wears.
Must be precisely balanced after assembly.

Double disc clutch.

What is it?
Also known as dual-clutch transmission (DCT) or twin-clutch gearbox is a type of semi-automatic or
automated manual automotive transmission. It uses two separate clutches for odd and even gear sets.
It can fundamentally be described as two separate manual transmissions contain within one housing
and working as one unit. They are usually automatic mode, and many also have the ability to allow
the driver to manually shift gears.

Type of cars that uses double disc clutch:

Race cars including F1, IndyCar, World Rally.

Most club racing, motorcycles, automatic transmission and some diesel locomotives.

There are two type of double disc clutch:

1. Two wet multi-plate clutches(bathed in oil for cooling purposes.)
Generally used for higher torque engines which can generate 350 newton metres and

more.
Example: Bugatti veyron.

2. Two dry single-plate clutches.

Generally suitable for smaller vehicles with lower torque outputs up to 250 newton
metres. However, while the dry clutch variants may be limited in torque compared to
their clutch counterparts, the dry clutch variants offer an increase in fuel efficiency,
due to the lack of pumping losses of the transmission fluid in the clutch housing

Car manufacturer that applies DCT:

BMW: M3 model, Z4( the Sdrive35i version) , 335is and 135i.

BYD: Sedan BYD G6.

Chrysler: Chryslers inline-4 and V6 Pentastar in the Dodge Dart and D-segment car in 2013.
FIAT GROUP: California and 458 Italia sportscars( Seven-speed dual wet clutch transmission)
Ford Motor Company: Ford Focus and Ford C-MAX(wet clutch PowerShift)
Volvo: Volvo S60, V50 and C30.( Powershift gearbox)

MEV321

Assignment: Clutch System

Name: Nathan Martinus
Matrix no: 2011474598
Group: Em1106T1
Lecturer: Muhammad Arif B AB Hamid
Pahmi