The document provides information on overhauling transmission systems for LCV vehicles. It discusses dismantling and reassembling procedures for various gearboxes including the GBS-380, GBS-550, and TA-70 transaxle. The summary discusses the key components covered in the document: 1) The document covers overhauling procedures for various gearboxes used in Tata LCV vehicles including the GBS-380, GBS-550, and TA-70 transaxle. 2) Dismantling and reassembly procedures are provided for each transmission system as well as inspections of individual components and the use of special tools. 3) Information is given on removing the transmissions

1. Technician Level 2 – Module 2
Clutch & Transmission Systems - LCV

2. Introduction
 Participant Name
 Dealership Name
 Location
 Experience in Tata Motors (In years & months)
 Specialization in which Models / Aggregates
 Hobbies
7/27/2022 TML 2

3. Program Objectives
At the end of this module the participants will be able to:
 Understand the construction and types of Gear Boxes used in LCV range of Vehicles
 State the differences and characteristics of each type of Gear Boxes
 Perform Overhauling of GBS-380 & GBS-550 Gear Boxes
 Perform Overhauling of Transaxle – TA -70
 Perform Maintenance Checks and Adjustments
 Perform Overhauling of 280 mm Dia Clutch
 Perform Important Adjustments & Settings on Clutch – 280 mm Dia & 330 mm Dia
7/27/2022 TML 3

4. Program Agenda
 Introduction to LCV Gear Boxes
– Introduction to GBS - 27 Gear Box
– Introduction to -GBS-40 Gear Box
– Introduction to GBS - 380 Gear Box
– Introduction to GBS-76 Gear Box
– Introduction to- GBS-550 Gear Box
– Introduction to TA - 70 Transaxle (FRT WD- Winger)
 Transmission Overhauling
– GBS- 380
– GBS-550
– TA -70
 Clutch System Overhauling
– 280 mm Dia Clutch
– 330 mm Dia Push Type Clutch
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5. (GBS-27, GBS-40, GBS-76, GBS-380, GBS-550 & TA 70)
Introduction to LCV Gear Boxes
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6. General Information
Introduction to GBS-27
7/27/2022 TML 6

7. GBS – 27- General Information
Weight : 82 Kgs.
Filling Capacity: 3.2 Ltrs.
Description:
 Specification:
– Model: GBS-27-5-7.36
– Ratios: 7.36 (three different ratios)
 Features:
– Synchro Mesh for 5 forward gears
– Sliding mesh for reverse gear
– Maximum torque of 27 mkg
 Weight of the Gear Box: 82 Kgs.
 Filling Capacity: 3.2 ltrs.
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8. GBS-27- Numbering System
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GBS-27-5/7.36
Transmit 27 mKg. of Torque
Five Speed
First Gear Ratio

9. GBS – 27 Gear Ratios
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Gear Ratios in Different Gears:
Gear Gear Ratio
Gear Ratio
Euro I
Gear Ratio
Turbo EX
GBS-27 -5 -7.36 GBS-27 -5 -7.36 GBS-27 -5 -7.36
1st 7.36 7.36 6.17
2nd 3.98 4.38 3.34
3rd 2.26 2.48 1.89
4th 1.39 1.58 1.32
5th 1.0 1.00 1.00
Reverse 6.67 6.67 5.58

10. GBS – 27 - Application
Tata 407 –LP/LPT-Turbo Ex.
Tata 709 – LP/LPT/SFC Turbo Ex. (BSII)
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11. General Information
Introduction to GBS-40
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12. GBS – 40- General Information
Weight of the Gear Box: 57 Kgs.
Filling Capacity: 5.2 ltrs
Description:
 Specification:
– Model: GBS-40-5-7.51
– Ratios: 7.51
 Features:
– Synchro Mesh for 5 forward gears
– Sliding mesh for reverse gear
– Maximum torque of 40 mkg
 Weight of the Gear Box: 57 Kgs.
 Filling Capacity: 5.2 ltrs.
 Gearbox Oil - SAE 80W90 grades
with 7% Anglomol
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13. GBS-40 – Numbering System
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GBS-40-5/7.51
Transmit 40 mKg. of Torque
Five Speed
First Gear Ratio

14. GBS-40 -Gear Ratios
Gear Ratios in Different Gears:
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Gear Gear Ratio No. of Teeth Gear Ratio No. of Teeth
712 EX 912 EX
Driveshaft Teeth 18 Drive shaft Teeth 17
1st 6.34 38/11 7.51 39/11
2nd 3.37 32/18 3.99 32/18
3rd 2.11 26/22 2.5 26/22
4th 1.28 20/28 1.51 20/28
5th 1.00 17/36 1.00 17/36
Reverse 6.93 6.93

15. GBS-40 - Application
LP/LPT/SFC 712
 LPT912 Turbo EX LPT/LP 1109 Turbo EX
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LPT/LP 1112 Turbo EX

16. General Information
Introduction to GBS-76
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17. GBS-76- General Information
Weight of the Gear Box: 57 Kgs.
Filling Capacity: 1.6 ltrs.
Description:
 Specification:
– Model: GBS-76 -5-3.87
– Ratios: 3.87
 Features:
– Synchro Mesh for 5 forward gears
– Sliding mesh for reverse gear
– Maximum torque of 16 mkg
 Weight of the Gear Box: 57 Kgs.
 Filling Capacity: 1.6 ltrs.
 Gearbox Oil - SAE 80W90 with 7% Anglamol
6097 by weight / API GL 4
 76 indicates the center distance between
main and counter shaft
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18. GBS-76 – Numbering System
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76 mm
(For illustration purpose only)

19. GBS-76 –Gear Ratios
Gear Ratios in Different Gears:
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Gear Gear Ratio
1st 3.87 & 4.1
2nd 2.36
3rd 1.37
4th 1.00
5th 0.82
Reverse 3.4

20. GBS-76 - Application
Xenon All Models
207 DI BS III EX
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21. General Information
Introduction to GBS-380
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22. GBS-380- General Information
Weight of the Gear Box: 64.5 Kgs.
Filling Capacity: 2.7 ltrs.
Description:
 Specification:
– Model: GBS-380-5-4.9
– Ratios: 4.9 & 5.19
 Features:
– Synchro Mesh for 5 forward gears
– Sliding mesh for reverse gear
– Maximum torque of 38 mkg
 Weight of the Gear Box: 64.5 Kgs.
 Filling Capacity: 2.7 ltrs.
 Lubricant Grade : SAE 80W90 with 7%
Anglamol 6097 by weight / API GL 4
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23. GBS-380 – Gear Ratios
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Gear Ratios in Different Gears:
Gear Gear Ratios Number of Teeth ( Main & Counter shaft
For 407 Turbo –Euro-
1
For 407 Turbo Ex –
Euro -II
For 407 Turbo –Euro-
1
For 407 Turbo Ex –
Euro -II
1st 4.9 5.19 37/13 38/13
2nd 2.84 3.01 33/20 32/19
3rd 1.79 1.89 27/26 23/24
4th 1.24 1.32 21/29 22/33
5th 1.00 1.00 - 18/36
Rev 4.77 5.05 36/13 36/13

24. GBS-380- Application
Tata LP-407/410 -12 Seater
Tata -407 /410 SFC
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25. General Information
Introduction to GBS-550
7/27/2022 TML 25

26. GBS-550-General Information
Aluminium housing
Filling Capacity: 5.8 Litres
Drain & Fill: 5.7 Litres
Description:
 Specification:
– Model: GBS-550-6- 6.9 (overall reduction)
– Ratios: 6.9 (Overall reduction)
 Features:
– G-550 – 6 speed with full remote gear shifting
– Synchro Mesh for 6 forward gears & 1Reverse
– 1st & 2nd Gear with double Synchro cone
– 3rd, 4th & 6th Gear Synchronizer on Counter
Shaft
– 6th Gear is Over Drive for Better KMPL
– Maximum torque of 550 Nm
– Aluminium housing for light weight
 Filling Capacity: 5.8 litres.
 Drain & Refill: 5.7 litres
 Lubricant Grade : SAE 80W90 with 7%
Anglamol 6097 by weight / API GL 4
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27. GBS-550- Gear Ratios
7/27/2022 TML 27
Gear Ratios in Different Gears:
Gear Shift Pattern:
Gear Ratio (6.9 Ratio Version)
Gears Number of Teeth Reduction Ratio Overall Reduction Ratio
1st 39/11 3.545 6.904
2nd 33/16 2.063 4.016
3rd 27/22 1.227 2.39
4th 21/28 0.75 1.461
5th 37/19 1.947 1
6th 25/58 0.431 0.84
Rev 24/11 x 36/24 2.18 x 1.5 6.373
2
1 3
6
5
4
N
R

28. GBS-550- Application
Tata Star Bus Ultra
Tata -1109/1112
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29. General Information
Introduction to Transaxle-TA-70
7/27/2022 TML 29

30. TA-70- General Information
Aluminium Housing
Filling Capacity: 2.1 Liter (Gears) & 1.4 Liter (
Differential)
Description:
 Specification:
– Model: TA-70 – 5.69 & 4.84
– Ratios: 5.69 & 4.84
– Final Drive Ratio: 4.11
 Features:
– Synchro Mesh for 5 forward gears & Sliding
mesh for 1Reverse
– Maximum torque of 190 Nm
– Aluminium housing for light weight
 Filling Capacity: 2.1 Liter (Gears) & 1.4 Liter
( Differential)
 Oil Used: 75W 90 Gears & 85 W 140
Differential
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31. TA-70- Gear Ratios
Gear Ratios in Different Gears:
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TC Engines NA Engines
Gears
No. of Teeth Drop
down
Ratio
31/24
Gear
Ratio
Gear
Ratio
CWP
No. of Teeth Drop
down
Ratio
32/23
Gear
Ratio
Gear
Ratio
CWP
FD
Ratio
Lay
Shaft
I/P
Shaft
Lay
Shaft
I/P
Shaft
1 45 12 1.29 4.84 19.91 45 11 1.39 5.69 23.39 4.11
2 35 19 1.29 2.38 9.78 37 17 1.39 3.03 12.45 4.11
3 30 24 1.29 1.61 6.64 31 22 1.39 1.960 8.06 4.11
4 30 34 1.29 1.140 4.68 33 34 1.39 1.35 5.55 4.11
5 24 37 1.29 0.84 3.44 29 37 1.39 1.09 4.48 4.11
R 38 11 1.29 4.46 18.34 38 11 1.39 4.81 19.75 4.11
RI 23

32. TA-70- Transaxle Layout
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33. TA-70 - Application
Tata Winger
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34. GBS-380
Transmission Overhauling
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35. Removal of Transmission from the Vehicle
Transmission – GBS-380
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36.  Transmission Removal Steps & Procedures from
the Vehicle
 Special Tools Required for the purpose
Removal of GBS-380 from the Vehicle
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Transmission Removal
from the Vehicle- GBS-
380

37. Dismantling the Gear Box
GBS-380
7/27/2022 TML 37

38.  Dismantling of GBS-380
 Dismantling the sub assemblies of GBS-380
 Inspection of Components
 Reassembling the GBS-380
Dismantling & Assembly of GBS-380
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Dismantling, Inspection
& Assembly of GBS-380

39. GBS-550
Transmission Overhauling
7/27/2022 TML 39

40. Dismantling the Gear Box
GBS-550
7/27/2022 TML 40

41.  Dismantling of GBS-550
 Dismantling the sub assemblies of GBS-550
 Inspection of Components
 Reassembling the GBS-550
 Special Tools required for Overhauling
Dismantling & Assembly of GBS-550
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Dismantling, Inspection
& Assembly of GBS-550

42. TA -70
Transaxle Overhauling
7/27/2022 TML 42

43. Removal of Transaxle from the Vehicle
Transaxle –TA-70
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44. Special Tools & Equipment's
7/27/2022 TML 44
Sl No Picture Special Tool Number Usage
1
Installing the taper roller
bearing use the bearing
seat pusher special tool
2
Removing Taper roller
bearing seat
3
Pinion Pre-loading shim
selection special tool
4
Differential Threaded ring
tightening Special tool

45. Special Tools & Equipment's
7/27/2022 TML 45
Sl No Picture Special Tool Number Usage
5 Drop down Gear lock
6 Locking Counter shaft
7 5th gear puller special tool

46.  Transmission Removal Steps & Procedures from
the Vehicle
Removal of TA-70 from the Vehicle
7/27/2022 TML 46
Transaxle Removal from
the Vehicle- TA-70

47. Dismantling the Transaxle( Winger)
TA-70
7/27/2022 TML 47

48. Dismantling the TA-70 –Transaxle (Winger)
 Mount the Gear box on the stand
 Remove the selector lever
 Remove the Reverse gear selecting cable
 Remove the Speedo cable
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49. Dismantling the TA-70 –Transaxle (Winger)
 Remove the retain plug, Spring & Ball of 5th Gear Selector Shaft
 Unscrew the Hex bolts & separate rear cover from the Transaxle housing

50. Dismantling the TA-70 –Transaxle (Winger)
 Tap gently and pull out 5th gear shifter shaft along with shifter fork and shifting sleeve
 Remove 3 retainer bolts from ½, ¾ and reverse shifter shafts
 Take out springs and balls
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51. Dismantling the TA-70 –Transaxle (Winger)
 Push out double Spring pin from1/2 – 3/4 shifter link , 5th Reverse shifter link
 Compress the spring on the selector shaft and pull out the plastic half locks
 Pull out the selector shaft from the housing
7/27/2022 TML 51

52. Dismantling the TA-70 –Transaxle (Winger)
 Bush with step is towards gear shift lever
 Bush without step is towards selector finger
7/27/2022 TML 52

53. Dismantling the TA-70 –Transaxle (Winger)
 Lock the 5th gear on the counter shaft and loosen the lock nut and take it out
 With the help of special tool puller the 5th gear on the counter shaft and take out Spacer
sleeve needle bearing washer Synchronizer body, retainer spring & synchronizer ring.
 Remove the snap ring on the main shaft and pull out the snap ring from the main shaft.
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54. Dismantling the TA-70 –Transaxle (Winger)
 Remove the spring pin of ½ and ¾ shifting lever
 Take out reverse gear shifting liver
7/27/2022 TML 54

55. Dismantling the TA-70 –Transaxle (Winger)
 Remove the Reverse Gear switch
 Unscrew all hexagonal bolts from gear box rear housing and take out
NOTE : DO NOT HAMMER THE HOUSING TAP GENTLY WITH MALLET TO SEPERATE
7/27/2022 TML 55

56. Dismantling the TA-70 –Transaxle (Winger)
 Push out the spring pin and rotate the ¾ shifter shaft
 Pull out the shifter shaft
 Remove the fork
 The same procedure should be followed for removing the shifter shaft and fork for the ½
shifter shaft
 Hold the Main shaft, Counter shaft and Reverse shaft together and take it out from the
housing
7/27/2022 TML 56

57. Dismantling the TA-70 –Transaxle (Winger)
 Dismantle 1-7, Clean and Inspect all the components. Replace worn out and damaged parts
 To remove the clutch shaft press the sleeve on the input shaft & and pull the clutch shaft
7/27/2022 TML 57
1.Lay shaft
2.Washer
3.Needle bearing
4.Spring
5.O ring
6.Dowel
7.Clutch shaft
8.Ball bearing
9.Circlip
10.Washer
11.Spacer
12.Needle bearing
13.5th Gear
14.Synchronizer ring
15.Retainer spring
16.Synchronizer sleeve
17.Washer
18.Lock nut

58. Dismantling the TA-70 –Transaxle (Winger)
 Dismantle 4th gear, Reverse gear with shifter with 3rd gear, 2nd gear, 1st gear and reduction
gear one by one with snap rings synchronizer assembly and spline washer
 Remove snap ring, spacer & ball bearing from speedo pinion end
 NOTE : Please take care of spline washers, snap rings and Synchronizer rings during dis
assembly as they are different
7/27/2022 TML 58

59. Dismantling the TA-70 –Transaxle (Winger)
 Remove the drop down gear cover
 Lock the drop down gear with the special tool as shown in the figure.
 Loosen the lock nut on pinion shaft and remove the nut.
 Remove the special tool.
 Unscrew the hexagonal bolts shown with red arrow mark (Intermediate gear box housing to
Clutch housing)
 Push out the Pinion shaft and dis-assemble the pinion shaft
7/27/2022 TML 59

60. Dismantling the TA-70 –Transaxle (Winger)
Combination gear :
 This gear works as shifter sleeve for 3rd
and 4th gear and Reverse gear on main
shaft
Synchro cone Gap:
 1st & 2nd = 1.2mm: 3rd,4th,5th-=
1.1mm
7/27/2022 TML 60
Groove on shifter sleeve
should be towards 2nd gear

61.  Dismantling of TA-70
 Dismantling the sub assemblies of TA-70
 Inspection & Adjustments
 Reassembling the TA-70
 On Vehicle Repair Procedures
Dismantling & Assembly of TA-70
7/27/2022 TML 61
Dismantling, Inspection
& Assembly of TA-70

62. Clutch System
7/27/2022 TML 62

63. Clutch System – LCV – Application Matrix
7/27/2022 TML 63
Sr.
No.
Parameters
215 Dia.
Clutch
240 Dia. Clutch 280 Dia. Clutch 310 Dia. Clutch 330 Dia. Clutch 352 Dia. Clutch
380 Dia.
Clutch
1
Supplier
Valeo
207 DI / Xenon Rx -
Exedy
Xenon 3L - LUK
India
LUK India Setco Setco Setco Setco
2
Type Single type dry
friction
diaphragm
type
Single type dry
friction diaphragm
type
Single type dry friction
diaphragm type
Single plate dry
friction diaphragm
type
A. Booster Assisted
Single plate dry
friction diaphragm
type
A. Booster Assisted
Single plate dry
friction diaphragm
type
Single plate
dry friction
Push type
3
Type of
Actuation Push type Push type Push type
A. Booster
Assisted
B. Push Type
A. Pneumatic
Booster
B. Push Type
Pull Type Push Type
4 Models 1. Winger
A1. Xenon 2.2L
BSIV (DOM.)
A2. Xenon 3.0L
(DOM.)
C1. 207 DI EX BS
II/III/IV
C2. 207 DI RX
C3. Xenon Pickup
C4. SFC 407 CNG
BSIII
C5. LP 407 BSII
C6. SFC 407 BSIII
A1. 407 Facelift BS III
A2. LPT/SFC 407 BS III
A3. SFC 407 Pickup BS II
A4. LP/LPT/SFC 407 BSII
A5. LPK 407 BS II/III
A6. Tata 410 EX
A7. LP 709 BS II/III
A8. LP 909 BSII/III A9.
LP 709 EX BSII
(Reinforced)
A10. SFC 407 CNG BSIV
B1. SFC 407 Pickup BS II
A1. LPK 909 BS III
A2. SFC 909 EX BS
III
A3. SFC 712 EX BS
III
A4. LP/LPT 712 EX
BS III
A5. LPT 709 BS III
A6. LPT 909 BS III
A7. LPT 909 H EX2
BS III
A8. LP 709 BS III
B1. LP 712 BS IV
Ac1. Starbus ULTRA
BS III
Ac.2. Tata ULTRA
BS III
Bc1. LPO 9.6T Y1,
12V
Bc2. LPO 9.6T Y1,
NG
Bc3. LPT 1109 CRDi
BSIII
Bb4. LPT 1109 Bs III
Ba. LPO 1613 BSIV
A1. LPT 1613
A2. LPT 1616
A3. SE 1613
A4. SK 1613
A5. SE 1616
A6. SK 1616
A7 LPK 1616
B1. LPO 1612C
B2. 1610/ 1616/
1612C/ 1612C RE
B3. 4018C
B4. 3015C
A. LPK
2518TC
B. LPT
2518TC

64. Types of Clutch
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Diaphragm Clutch Hydraulic Clutch Actuation
Hydraulic & Air Clutch Actuation
Spring Clutch

65. Types of Clutch
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Clutch plate type Clutch pressure plate Release bearing
Ceramic Spring Type Oil Lubricated
Organic Diaphragm Type Grease Lubricated
Self Lubricated

66. Clutch System Overhauling
Clutch System -280 mm Dia.
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67. Clutch System -280 Dia- Construction
 Single Disc Dry Clutch
 Diameter : 280 mm
 Pressure Plate Assembly : Diaphragm
Spring Type
 Clutch release Bearing : Self Centering Type
 Clutch Actuation : Hydraulic Master/Slave
Cylinder
 Clutch Adjustment : Self- Adjusting
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68. Clutch System -280 Dia- Components
Sl No.
Assembly
Pressure Plate Clutch Plate Clutch Actuation
1 Pressure Plate Side Plate Clutch Pedal
2 Diaphragm Rivets Facing Rivet Adjusting Eccentric Pin
3 Fulcrum Ring Facing Clutch Release Fork
4 Cover Damper Spring Brake Cum Clutch Fluid Container
5 Diaphragm Spring Hub Clutch Master Cylinder
6 Rivets Intermediate Plate Clutch Slave Cylinder
7 Straps Washer Bleeding Nipple
8 Carrier Plate Push Rod
9 Segment Clutch Pedal Stop
10 Rivet
11 Washer
12 Wave Washer
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69. Clutch System –Pressure Plate Assembly Specification
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Sl No Description – Pressure Plate Unit
Value
New Condition Worn Condition
1 Clutch Plate Diameter mm Ø 281 Ø 281
2 Minimum Clamp Load N 8150 ( Mean Curve) 7250 (Mean Curve)
3 Release Load (NEW) N Max. 2400 Max.2640
4 Release Load (WORN) N Max.2950 Max.3250
5 Release Bearing Dia mm Ø 64 Ø 64
6
Lift of Pressure plate for 10 mm
travel
mm
1.7 1.7
7 Set Height when new mm 52.5 + 1.5 52.5 + 1.5
8 Finger tip run out mm 0.8 max 1.2 max
9 Overall Clutch size mm Max. 334.5 Max. 334.5
10 Dowel hole size/PCD/Nos. mm/mm/nos.
8.025+0.05/Ø
313.995/3X
8.025+0.05/Ø
313.995/3X

70. Clutch System –Pressure Plate Assembly Specification
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Sl No Description - Pressure Plate Unit
Value
New Condition Worn Condition
11 Mounting hole size/PCD/Nos. mm/mm/nos.
8.7+ 0.1 / Ø
314.07/3X
8.7+ 0.1 / Ø
314.07/3X
12 Diaphragm type - Goose neck Goose neck
13 Total clutch height mm 60.5+ 0.2 60.5+ 0.2

71. Clutch System – Clutch Disc Assembly Specification
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Sl No
Description – Clutch Disc
Assembly
Unit
Value
New Condition Worn Condition
1 Outer Diameter (Facing) mm Ø 280 + 1 Ø 280 + 1
2 Inner Diameter (Facing) mm Ø 165 + 0.5/1 Ø 165 + 0.5/1
3 Clutch Plate thickness (New) mm 10.3 10.3
4 Clutch Plate thickness (Worn) mm 7.5 7.5
5 Facing Material - Valeo F 510 Valeo F 510
6 Max. Torque/Max. Twist angle mKg/deg 52/4.6° 47/4.6°
7 Number of Stages Nos Single Single
8 Level Dimension mm 6.5 + 1 8.5 + 1
9 Hub Length mm 35 + 0.5 8.5 + 1/1.5
10 Spline -
A 10×28×35 DIN
5464/65
A 10×28×35 DIN
5464/65

72. Clutch Actuation System & Components
Clutch Actuation Mechanism :
 Hydraulically operated clutch has been fitted on this vehicle. Hence the clutch is adjusted
automatically. Basic adjustment of the clutch control mechanism is necessary after the pedals
have been worked on or after the removal of the master cylinder.
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1 Clutch Pedal
2 Adjusting Pin
3 Clutch Release Fork
4 Clutch Fluid Container
5 Clutch Master Cylinder
6 Clutch Slave Cylinder
7 Bleeding Nipple
8 Push Rod
9 Lock Nut

73. Clutch Actuation System & Components
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Slave Cylinder
Master Cylinder
Master cylinder is having fluid bottle and attached to pedal. It compresses the
oil and raises pressure up to 55 bar and send to slave cylinder
Slave cylinder is attached to clutch fork and actuated by pressure developed in
master cylinder

74. Clutch Booster Mechanism
 In order to reduce the clutch pedal effort, 70mm dia clutch booster assy is introduced in place
of hydraulic clutch slave cylinder. Clutch booster is a pneumatic assisted clutch slave cylinder.
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Model Clutch Pedal Travel (mm) Clutch Booster Travel (mm)
709 110 10 - 12 mm
909 110 10 - 12 mm
1109 110 10 - 12 mm
Y1 100 10 - 12 mm
1613 152 20 - 22 mm
2518 124 20 - 22 mm

75. Safety Procedures & Cautions to be Followed
 Never blow compressed over the clutch plates to clean them.
 Clutch linings should not be replaced individually – Entire clutch disc to be replaced with
genuine parts.
 Ensure clutch facing material is not contaminated with oil or grease to prevent unnecessary
slippage of clutch
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76. Checks to be done on the vehicle before Clutch
Removal
Sl No Checks to Be Done Corrective Action
1
Check for smooth engagement and smooth
return of pedal
Pedal return should be smooth and there
should be no stick slip. Ensure the presence of
pedal return spring. Ensure that the pedal
linkages and bushes are greased.
2 Check the pedal free play
Should be 2 to 3mm. If not adjust the pedal
linkages to get the required play.
3
Check for full travel (As per drawing specification)
of the pedal to the bottom of the floor.
There should be no obstructions like foot rest
etc.
4
Start the engine and check what point of pedal
travel the clutch is released and engaged
Clutch engagement and disengagement should
take place between to 2/3rd the pedal travel
5 Check the movement of master and slave
cylinders.
Movement should be smooth and should not
be sticky
6 Check if bleeding of hydraulic cylinders are done. Bleed the system if pedal is spongy
7 Check for the stroke of the slave cylinder by
depressing the clutch pedal fully
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77.  Clutch System Removal Procedure from Vehicle
 Removal Of Clutch Actuation Mechanism
 Dismantling Of Master Cylinder
 Dismantling Of Slave Cylinder
 Inspection of Clutch Components
– Inspection Of Master Cylinder
– Inspection Of Slave Cylinder
 Assembling Of Master Cylinder
 Assembly Of Slave Cylinder
 Installation Of Clutch On Vehicle
Clutch System Overhauling – 280 mm Dia
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Clutch System
Overhauling – 280 mm
Dia

78. General Maintenance of Clutch System
 Maintenance of clutch includes adjustment of pedal stopper bolt, checking oil level and
bleeding the system for defect free operation on clutch actuation mechanism and periodic
lubrication
Driving:
Following driving conditions will affect performance of clutch
 Clutch Riding
– Using clutch pedal as foot rest by keeping foot constantly on pedal while driving will cause partial
clutch disengagement. It will result in slipping of the clutch disc and premature failure of the clutch.
 Permitting the clutch to slip too long
– Half clutch driving and thereby permitting the clutch purposely to slip too long will have the same
result as clutch riding
 Sudden clutch engagement at higher engine speed specially while moving out stranded
vehicle will cause severe instantaneous clutch loading, resulting in clutch slippage and
burning of the lining. Starting the vehicle in first gear under such conditions will avoid such a
problem. Always start vehicle in first gear.
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79. General Maintenance of Clutch System
Operating Conditions:
 Vehicles operating on shorter runs, city operations, off highway and operations in hilly
terrains are obviously subjected to more number of clutch operations and thereby higher
clutch wear.
Clutch Disengagement And Disengagement Test
 During the above test, when vehicle is in motion, depress clutch pedal fully without changing
accelerator pedal position. If engine speed increases immediately, perfect clutch
disengagement is indicated. Further, release the clutch pedal suddenly. If the vehicle moves
forward with a little jerk, perfect clutch engagement is indicated
 Caution : This test should be carried out with utmost care because sudden release of clutch
might cause heavy jerk and damage to clutch lining.
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80. General Maintenance of Clutch System
Clutch Slippage Test:
The following methods are used to confirm clutch slippage:
 Drive vehicle in 1st or 2nd gear at maximum speed corresponding to that gear. With
accelerator pedal fully pressed, apply brake gradually with left foot. If engine stalls, it means
that clutch does not slip
 Drive loaded vehicle in3rd gear on level ground and let vehicle speed drop down to
approximately 15 kmph / 9mph. Now press accelerator pedal full. With slipping clutch, vehicle
speed will not pick up and also clutch burning smell will be felt. If this does not occur and
vehicle picks up speed. It indicates that clutch does not slip.
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81. Important Settings & Adjustments
Clutch Pedal Height & Free Play Adjustment:
 Clutch pedal free play is due to clearance
between plunger & push rod of master
cylinder. This cannot be adjusted. It is built in
design feature.
 Loosen lock nut for master cylinder push rod
fork.
 Slide back dust cover.
 Rotate master cylinder push rod till desired
height of pedal is achieved.
 Tighten lock nut for push rod fork.
 Check pedal stroke. It should be 130 mm. If
not adjust pedal stroke with pedal travel
adjusting screw( Stopper Bolt) & lock it with
lock nut.
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82. Important Settings & Adjustments
Clutch Pedal Height & Free Play Adjustment
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1. Clutch Pedal
2. Cl pedal Adj. screw
3. Cl release fork
4. Reservoir
5. Master Cylinder
6. Slave cylinder
7. Bleeding pt.
8. Push Rod
9. Lock Nut
Cl Pedal height adjustment
Measured with a scale

83. Clutch Release Bearing Lubrication
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Felt Pad Oiling photo Greasing type CRB
Fill oil this point.

84. Clutch Fluid Filling & Bleeding The System
1. Fill the Container with clean brake fluid.
2. Connect the S/Cyl. bleeding nipple with the
tube to a glass jar with fluid.
3. Press the clutch pedal 3 to 4 time to full stroke,
watch the fluid level in container & keep
adding.
4. Hold the pedal pressed, loosen the S/cyl,
bleeding screw till all air bubble expel. Tighten
the nipple.
5. Repeat sl.no 3 & 4 till the air bubble cease to
appear.
NOTE: Ensure that the fluid level in container does
not fall below ‘MIN’ marking throughout the
bleeding operation. If it drops down to ‘MIN’
marking, top up with brake fluid up to ‘MAX’
marking.
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Clutch Master Cylinder
Clutch Slave Cylinder

85. Clutch System Overhauling
Clutch System - 330 mm Dia.
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86. 330 Dia Clutch Adjustment
 The lever height are set by turning the adjusting nuts while at same time holding the lock nut
with a spanner.
 The position of the three lever in the case of 330 dia clutch with a cast iron cover is check
from the flat surface of the flywheel or arbor press to top of the collector ring at minimum
three point.
 This dimension should 53mm +/-0.2mm and run out of finger within 0.4 mm.
 This dimension can also be verified by checking the dimension of 32 mm +/- 0.2 mm from the
top face of cover raised lugs up to the collector ring.
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87. Clutch Overhauling - 330 mm Clutch
 Remove cast iron cover & 9 pressure spring.
 Remove circlip & washer from the pressure plate pins.
 Remove the release levers, dismantle the eye bolt pins from the eye bolts & adjusting nuts
from eyebolts.
 Press or knock out the needle bearings in the eyebolts & pressure plate.
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Mounting Bolt Toggle Tool
Acceptance
norm
Pressure
spring
Load @ 38.86
mm
122 kg
Free Length 71 mm/min

88. Clutch Specification - 330 dia
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Description
Nominal
Value (mm)
Limit
Tolerance
(mm)
Correction
and Remark
Driven Disc
Assembly
Facing assembly thickness (when independent) 10.8 6.8 Replace
Flatness 0.60
Correct or
Replace
Hub spline play in rotating direction Replace
Pressure
Plate
Gap between ring cover and Pressure plate Slots 0.10 0.25 Replace
Height from friction face to the top of the Pressure
Plate pin
38.4 37.6 Replace
Minimum free length of pressure Springs 71 Replace
Pressure Plate Lever height (A) From Flywheel face
up-to the Collector Ring (B) From top of the cover
raised lug up-to collector ring.
53.0
32.0
± 0.2
± 0.2
Adjust
Adjust

89. Clutch Specification - 330 dia
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Tightening Torque
Part to be tightened Thread size O.D. x Pitch (mm) Tightening torque Nm (Kgfm)
Clutch Clutch Cover mounting bolt M8 X 50 47 to 54 (4.7 to 5.4)
Cover Pressure plate eye bolt lock nut 110 to 120 (11 - 12)

90. All The Best!!!
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