2. Index
●1.Function of clutch system.
●2.Basic component of clutch.
●3.Clutch handling procedure.
●4.Clutch failure diagnosis.
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3. WHAT IS CLUTCH?
●“Clutch is a mechanism which enables the transmission
of the rotary motion of the driving source to the driven source; and
enables the disengagement of the two sources from each other when
required.”
1. Torque Transmission.
2. Disengagement of two sources from each other when required.
PURPOSE?
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4. • Transmit engine torque .
• Disengage the engine from the
gearbox.
• Allow smooth gearchanges .
• Enable smooth take up of drive.
• Absorb torsional vibration.
• Provide overload protection for the
gearbox
CLUTCH FUNCTION?
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6. BASIC COMPONENTS OF CLUTCH COVER ASSEMBLY
Cover
Pressure plate
Diaphragm spring
Drive strap
Fulcrum ring
Rivet
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7. Clutch facing or lining
Clutch plate
Hub flange
Splined hub
Damper spring
Retainer plate
Segment
BASIC COMPONENTS OF CLUTCH PLATE
Stop pin rivets
Plastic washer
Tap plate
Belleville washer
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8. Central element of the clutch .
Forms a friction system with the
engine flywheel and pressure plate.
In a coupled condition it is compressed
between the flywheel and pressure
plate.
Drive is transmitted via the teeth of
the hub to the gearbox input shaft.
DRIVEN PLATE / CLUTCH DISC - BASICS
Function
Enable smooth take up of drive
Enables quick gear changes
Dampens torsional vibrations
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9. Torsion Dampers have the task of
absorbing torsional vibrations
between the engine and gearbox.
- Unlike electric motors or
turbines, internal combustion
engines do not produce
constant torque
- The constantly changing
angular speeds of the
crankshaft produce vibrations
that are transmitted via the
clutch and transmission input
shaft to the transmission itself.
- Torsion Dampers are specifically
engineered to each vehicle.
CLUTCH PLATE – TORSION DAMPER FUNCTION
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10. Tasks
Provide smooth take up of drive
Function.
The clutch pressure plate must first
compress the cushion springs against
the flywheel.
Since this pressure develops slowly the
engagement procedure is extended and
the transmission and engine speed can
be matched evenly by flexing of the
cushion springs.
CLUTCH DISC – CUSHION SPRING
Advantages
Jerk free starting .
Favourable wear characteristics Better
wear pattern and even heat distribution
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12. Only prescribed clutch set should be used
for that particular application.
While fitting the clutch, first the driven plate
has to be placed and centered using the Input
shaft (or a suitable tool) and then the cover
should be bolted to the flywheel.
The mounting of the cover assembly on the
flywheel should be done uniformly with multi
spindle tightening. After mounting the assembly,
the bolts should be properly torque (as per
spec).
The assembly should not be dropped at any
point of time, if dropped it should be scrapped.
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13. The assemblies should not be handled with
dirty hands (oily / greasy).
The assembly should not be hammered while
mounting or any point of time.
Heavy objects should not placed on the
assembly.
The friction surface should not be damaged
and free from oil.
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14. Gear Box Side
Flywheel Side
Ensure the driven plate is fitted the correct way
round ( Flywheel side / Gear box side).
Ensure the driven plate slides easily on the Input
shaft. Apply a thin coating of grease onto the
spline
(as per spec) if already not applied.
Flywheel surface should be free of oil / dirt, etc.
Stacking of the assembly should not be done
on diaphragm fingers
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15. Not more than 5 assemblies should be stacked.
Bolting of the Cover assembly to the
Flywheel should be done uniformly
Incorrect alignment of the clutch cause judder or
fail to disengage immediately hence the clutch
should always be checked for correct alignment
on the flywheel.
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18. Cause :
Over heating due to clutch slip
Incorrect driving practice
Clutch riding (Half pedal)
High gear selection during veh starting.
Overheating of pressure plate as a result
of prolonged clutch slip.
2. Improper free pedal play.
3. Abnormal use of clutch as a break.
4. Hold the vehicle in slop using the clutch.
Clutch burnt / Broken pressure plate
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19. 5. Clutch slips due to worn facing.
6. Stiff seized release mechanism.
7. Facing contaminated with oil & Grease
(Damage oil seal).
8. Over loading.
9. Faulty release system
10. Insufficient release bearing clearance.
Clutch burnt / Broken pressure plate
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20. Cause :
Oil on facing
- Faulty oil seals
Release mechanism seized or faulty.
If the flywheel has been reworked the
pot depth was not considered or the
bolting surface had not been
reworked.
Facing burnt
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21. 1. Incorrect grade of grease or No grease
used in hub spline.
2. Damage release bearing.
3. Release bearing not proper align with
guide sleeve.
4.Burnt & Worn out clutch plate.That
leads to high release load.
5.Master / Slave cylinder / Hose leakage.
6.Release bearing & Release fork worn out.
7.Clutch cable damage.
8.Wear in actuation system.
Clutch hard / Pedal hard
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32. 1.Worn diaphragm spring finger.
2.Damage release system.
3.Incorrect fitment.
4.Tangential strap bend / broken.
5.Damage spline profile.
6.Damage driven plate ( Run out in driven plate ).
7.Release bearing worn out or Damage.
Gear shifting hard
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34. 1. Transmission out of alignment, causing main drive
gear bearing or bushing to be misaligned with pilot
bearing .
2. Worn clutch plate spline's .
3. Worn main drive input shaft spline's .
4. Excessive backlash in transmission .
5. Dry or worn pilot bearing .
6. Structural failure in clutch plate ( Damper spring ).
7. Excessive crankshaft end play.
8. Flywheel housing misaligned.
Noise
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35. Cause:
Improper Handling
- Dropping the clutch prior to or
during fitting
Fitting fault
- Flywheel not held secure when
bolting on clutch cover.
Play in the drive line
- Worn drive line coupling
Incorrect driving practice
- Tow starting in 1st & 2nd gear
- Incorrect gear selection
Improper handling
Tangential strap bend
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36. Cause :
Fitting fault
- Driven plate fitted the wrong way
round
- Incorrect driven plate
- Flywheel machined too excess.
Cause :
Release bearing seized.
Faulty release mechanism.
Incorrect adjusted release
mechanism.
Wear marks on the hub
Worn diaphragm spring fingers
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