1.

GENERAL:

Clutch System

The Clutch system consists of a clutch system and clutch actuation

system. The clutch system normally transmits power from the engine to the
transmission and performs the following functions when the clutch pedal is
operated.
• Transmitting Engine power smoothly to the transmission when the vehicle
is started.
• Connecting and disconnecting engine power while gear shifting.
The Clutch system is divided into the Clutch disc that transmits engine
power to transmission input shaft and the pressure plate that forces the clutch
disc against the engine flywheel.
While clutch pedal is released, outside spring force of the diaphragm
spring pushes the pressure plate on the flywheel with the pivot ring as the
fulcrum. The clutch disc then rotates with flywheel to transmit power to the
transmission input shaft that supports the clutch disc.
When the clutch pedal is depressed, hydraulic pressure from clutch
master cylinder moves the clutch booster piston along with the pneumatic
pressure.
The force generated from booster pushes the clutch release bearing via
clutch release fork assembly in order to push diaphragm spring fingers.
The outer side of the diaphragm spring is pulled back with the pivot ring as
the fulcrum. This causes the strap plate, which is connected at one end to the
clutch cover, to pull back the pressure plate.
This produces clearance between the clutch disc and the flywheel
(engine) and engine power is no longer transmitted to the transmission.
Clutch Actuation System:

When the clutch pedal is depressed, the foot pressure is transmitted to the
clutch master cylinder generating hydraulic pressure to actuate the clutch
booster. The clutch booster converts the hydraulic pressure into push rod thrust
with the help of pneumatic pressure, thus disengaging the clutch to cut off the
power transmission line. The clutch transmits engine power smoothly to the
transmission when vehicle is started.

Clutch Master Cylinder:

When pedal is depressed:

The reservoir supplies fluid to the system through a non-return valve. The
smaller relief or compensating port connects the reservoir directly with the
cylinder when the piston is in release position. When foot pedal is in the released
condition, fluid may flow from reservoir through non-return valve into the master
cylinder, supply lines and clutch booster to make for any fluid that may be lost or
to compensate for shrinkage cooling of the fluid. In addition to that, when fluid
expands because of heat, the excess passes back into the reservoir through the
relief port, thus preventing undesirable pressure rise in the system. When the
clutch pedal is depressed, the master cylinder piston moves forward to force fluid
under pressure into the system, the compensating port is sealed out of the
system.

When the pedal is released:

When the pedal is released, the return spring quickly forces the piston
back against the piston stop. Since the fluid in the lines return rather slowly, a
vacuum tends to form in the cylinder in front of piston. This causes the primary
cups to collapse to allow the fluid to flow from the reservoir through the filler port
past the piston. In this way a complete column of fluid is always maintained
between the master cylinder piston and clutch booster piston ready for next
clutch application. Since the hole is provider in the filler cap, the atmospheric
pressure causes the flow from reservoir. When the fluid in the line returns, the
excess flow is directed into the reservoir through the relief port as already
discussed.

Clutch Booster:
The clutch booster connects the clutch according to ups and downs of the
hydraulic pressure generated by the master cylinder, which the clutch pedal
controls.
The construction of the clutch booster is illustrated here.
The clutch booster requires adjustment of free travel (the clearance between the
release bearing and the diaphragm spring of the clutch cover). A specified
amount of play is provided in the pedal-to-piston linkage to ensure the complete
return of the piston to its stop, thus avoiding the possibility of blocking the
compensating or relief port in the release position.

Theory of operation:
1) When not in operation:
When fluid pressure is not applied from clutch master cylinder, the clutch
booster will remain in its normal position due to diaphragm spring and lever
spring tension.

2)When in operation:
 Clutch can not be disengaged properly

Check operating mechanism

Is air trapped in the oil line Bleed the system

Check for leaks Correct leaks or replace faulty parts

Check clutch pedal play Adjust

Check clutch master operation Repair or Replace

Check clutch booster operation Repair or Replace

Check clutch proper (disassemble clutch assembly and check)

Check for pilot bearing damage and poor Replace

Lubrication

Check for release bearing damage Replace