CLUTCH SERVICE

Teknik Kendaraan RinganSemester 3 th Class XI

Kompetensi Kejuruan

SK-KD 7TH

DIAGRAM ALUR PENCAPAIAN KOMPETENSI

SERVICING CLUTCHES

OBJECTIVES

Diagnose clutch-related problems.Inspect, adjust, replace clutch linkage.Inspect, adjust, repair, and replace clutch

slave and master cylinders, & lines.Inspect, adjust, and replace release bearing

lever, and pivot.Inspect and replace pressure plate.

OBJECTIVES

Inspect and replace clutch disc assembly. Inspect and replace pilot bearing. Inspect or replace flywheel ring gear. Inspect block, bellhousing, case surfaces. Measure flywheel runout, and crank endplay. Measure clutch housing-to-block runout. Inspect, replace, align power train mounts.

CLUTCH PROBLEM DIAGNOSIS

The more information you have, the easier it is to properly diagnose it.

Talk to the customer, ask questions.Road test the vehicle with the customer

driving, if possible.Look for driving habits that cause failure.Listen carefully to changes in the noise.

TROUBLESHOOTING GUIDE

NoisesBindingSlippagePulsationChatter

CLUTCH SLIPPAGE

Engine speed increases vehicle speed does not.

Slipping is caused by: Improper adjustment (too tight) Worn disc Contamination of the disc (oil)

Adjustment clearance decreases with disc wear.

Flywheel

Blue “Hot” Spots

Worn Clutch Disc

Uneven Wear

A Blue Pressure Plate

CLUTCH CHATTER

Clutch chatter is a shaking or shuddering.Clutch chatter is cause by:

Broken motor mounts Glazed clutch disc Worn U-joints Worn pilot bushing

OTHER CLUTCH NOISES

Most clutch noises are caused by bearings and bushings.

Bushings squeal or howl.Bearings grumble or grate.Misalignment is a common cause of clutch

problems.

CLUTCH VIBRATES

Clutch vibration can occur at any clutch position.

Can “feel” the vibration, and sometimes hear it also.

DRAGGING CLUTCH

Dragging results from the clutch not completely disengaging.

Maximum spin down time 5 seconds.Dragging is caused by:

Warped disc or Pressure plate Loose disc facing Incorrect clutch pedal adjustment.

PULSATING CLUTCH PEDAL

Pedal pulsation s a rapid up-and-down movement of the clutch pedal as the clutch engages or disengages.

Pulsating is caused by: Broken, bent, or warped release levers. Misaligned bell housing. Warped pressure plate, disc, or flywheel.

BINDING CLUTCH

Clutch pedal does not operate smoothly.Possible causes of binding are:

Worn front bearing retainer. Dirty or worn input shaft splines. Bent or worn linkage.

MECHANICAL CLUTCH CONTROLS

Worn bushings, bent rods, broken springs, and damaged cotter pins can cause excessive pedal effort when operating the clutch.

Free-play decreases as the clutch disc wears.

Worn linkage makes free-play adjustments inaccurate.

CABLE

FREE-PLAY ADJUSTMENT

Free play is the clearance between the clutch release fingers and the release bearing.

Free-play is measured at the pedal.Free-play is critical to clutch life.Insure return springs are in place.

SELF ADJUSTING

HYDRAULIC CLUTCH CONTROLS

Hydraulic clutch components are serviced like hydraulic brake components.

Common hydraulic problems are: Fluid leaks Worn-out piston seals Air in the system Corrosion buildup

HYDRAULIC

SLAVE CYLINDER

ADJUSTABLE SLAVE CYL.

Slave Cylinder

CLUTCH DISC

Clutch disc transfers power from the flywheel to the transmission input shaft.

Disc must remain free of oil.Clean hands.Most clutch discs contain Asbestos.If clutch disc is removed, replace if more

than 50,000 miles.

FLYWHEEL

Scored flywheels can be resurfaced.Check flywheel runout.Check crankshaft endplay.Clean oil and abrasives from flywheel.Check ring gear teeth.Mark flywheel and crankshaft for reassemble.

Flywheel

                                                                                                 

REMOVING THE CLUTCH

CautionMark driveshaft before removal.Caution AsbestosWarning check bolt length.Match new parts with old parts

PILOT BUSHINGS

Three Types Bushings Ball Bearings Torrington Needle Bearings

Use a tap to remove Bushings.Use a puller to remove bearings.

Pilot Bearing/ Bushing

RELEASE BEARING

Three Types Non Constant Running Release Bearing

• Adjustable Mechanical Linkage• Adjustable Hydraulic• Adjustable Cable

Constant Running Release Bearing• Self Adjusting Cable • Non Adjustable Hydraulic System

Internal Hydraulic Release Bearing (Pg 86)

Page 84

Mechanical Release Bearing

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