1. Manual Drivetrains and Axles CHAPTER Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch SEVENTH EDITION Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Diagnosis and Service 5

2. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Tech Tip The Tape Measure Trick To easily make a free clutch pedal travel measurements try this 1. Hook the end of a tape measure onto the pedal, and run it through the steering wheel. Note the reading at the steering wheel as the pedal is depressed through its travel. 2. Clutches that use hydraulic or cable linkage should have a small amount of free travel, whereas rod and lever linkage clutches should have about one inch (25 mm) free travel.

3. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–1 A typical cable operated clutch adjustment location.

4. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–2 A typical clutch master cylinder and reservoir mounted on the bulkhead on the driver’s side of the vehicle. Brake fluid is used in the hydraulic system to operate the slave cylinder located on the bell housing.

5. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–3 Clutch fluid is similar brake fluid.

6. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Real World Fix The Case of the Stuck in Gear Jeep A Jeep Wrangler (120,000 mi) sometimes got stuck in first or reverse, and the only way to get it out of gear is to shut the engine off. The transmission shifted okay most of the time. Thinking that clutch or related components were the most likely cause, the transmission was removed, and an inspection revealed a seizing pilot bushing. Replacement of the bushing fixed this problem. The pilot bushing did not allow the input shaft to move independently of the flywheel when the clutch was depressed.

7. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Real World Fix The Case of the Stretched Shift Cable The clutch on a Dodge Ram pickup (260,000 km) did not release completely. Adjusting the cable helped, but the end of the adjustment was reached. The transmission and clutch were removed. The clutch was carefully inspected, and it showed little wear and no damage. After reading some similar cases on www.iatn.net a new cable was purchased, and it was determined that the old cable had stretched. Installation of the new cable repaired this problem.

8. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Real World Fix The Case of the Broken Chevrolet Clutch The clutch in a Chevrolet HHR (119,000 mi) would not disengage. A broken pressure plate or clutch disc was suspected, so the transaxle was removed. Inspection showed normal clutch wear, nothing to prevent disengagement. A new pressure plate, disc, and throwout bearing were installed, and the flywheel was machined. The clutch still would not disengage. A small leak was found at the slave cylinder, so the entire hydraulic system was replaced with an OEM assembly. The new assembly was full of fluid, so bleeding was not necessary. The slave cylinder push rod travel has normal movement during clutch pedal travel application. At the suggestion of the parts supplier, a flywheel shim was installed to compensate for the thinner machined flywheel, but this did not help. Close inspection revealed that the release fork was bent and worn. Replacement of the fork and its bushings fixed this problem. It is important to spend a few minutes inspecting all of the clutch components to ensure a complete and proper repair.

9. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–4 A typical clutch kit, which includes the clutch disc, pressure plate, and release (throwout) bearing as well as grease for the spline and a clutch disc alignment tool.

10. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Warning The clutch driven disc may contain asbestos, which is known to be a cancer causing agent. Never clean clutch surfaces with compressed air. Avoid inhaling any dust from any clutch surface. When cleaning the clutch surfaces, use a commercially available brake cleaning fluid.

11. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–5 An old input shaft obtained from a disassembled transmission can be used to force the old pilot bushing out.

12. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–6 Using an abrasive disc to remove the glaze and to restore the proper surface finish to a flywheel.

13. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–7 A dial indicator set up to measure flywheel face or axial runout.

14. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Real World Fix The Case of the Stepped-Type Flywheel The clutch in a 2005 VW (107,000 mi) has been replaced and the flywheel was resurfaced at the same time. But now there is noticeable clutch chatter. The technician was told that during the flywheel resurfacing, only the clutch mating surface was machined. The technician feels that the step height could be incorrect, but could not find the specification. After contacting international Automotive Technician Network (iATN), a fellow technician provided the step-height specification. A check of the flywheel showed that its step was at the limit, but the clutch surface also had 0.003 inch of runout. Machining the flywheel fixed this problem.

15. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–8 The thickness of the clutch disc facing can be measured using a vernier caliper.

16. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–9 The overall disc thickness can be measured using a vernier caliper by first compressing the marcel spring using pliers.

17. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–10 The active radius determines the torque capacity of a clutch disc. Therefore, a narrower band of friction material at a further distance from the center may have improved torque capacity over a clutch disc that has a wider band but has a shorter active radius.

18. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Frequently Asked Question Why Is the New Clutch Disc Use a Thinner Band of Friction Material? Sometimes a replacement clutch disc looks totally wrong compared to the original. The wise technician always checks that the new part is the correct part before installing it. By using a thinner band of friction material, the centerline of the disc is further from the center. This distance is called the active radius. The more the distance between the centerline of the friction material and the centerline of the clutch disc, the higher the torque capacity of the clutch disc. Therefore, some replacement clutch discs may have a different appearance compared to the original. Double check with the supplier that the replacement clutch disc is designed for the vehicle being serviced before installing the new part. ● SEE FIGURE 5–10.

19. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–11 The dial indicator has a lever added to check clutch housing bore runout. Excessive runout can be caused by damaged or missing dowels in the engine block. If the dowels are okay, excessive runout can be corrected by installing eccentric dowels.

20. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–12 A summary of the entire rear-wheel-drive clutch replacement procedure.

21. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Real World Fix The Case of the Clogged Hose A Chevrolet K30 pickup (157,000 mi) came in with no clutch operation. The hydraulic system was bled, and the clutch tested. But during a road test, the clutch would no longer release. The clutch master cylinder, slave cylinder, and connecting hose were replaced, but the problem was still there. The technician blocked the outlet line of the master cylinder, and a solid clutch pedal proved that the master cylinder worked properly. Closer inspection showed that there was no fluid movement at the reservoir when the clutch pedal was applied. Replacement of the hose between the reservoir and the master cylinder fixed this problem.

22. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Figure 5–13 Gravity bleeding a hydraulic clutch. Opening the bleeder valve should allow air to escape and then fluid should flow.

23. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Real World Fix The Case of the Missing Bleeder The clutch failed in the Nissan 300ZX (181,000 mi) because the clutch arm pivot ball broke, which allowed the slave cylinder to come apart. The broken part along with the slave cylinder, clutch disc, pressure plate, and release bearing were replaced. But, the clutch pedal would go the floor without releasing the clutch. The clutch master cylinder was replaced, and a clutch adjustment was made. The clutch worked so the vehicle was returned to the customer, but a few days later it returned with a slipping clutch. The technician discovered that a bleeder screw was located near the right headlight. Opening this bleeder let a lot of air out of the clutch line. Completely bleeding the clutch along with a free travel readjustment fixed this comeback.

24. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 1. The first step in the process of replacing the clutch on this Chevrolet S-10 pickup truck is to remove the negative battery cable.

25. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 2. Remove the shifter mechanism inside the vehicle. This step may involve removing the center console and other components.

26. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 3. Mark and then remove the driveshaft.

27. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 4. Remove the exhaust pipe if needed. It was needed in this case, according to service information.

28. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 5. Remove the transmission mount fasteners.

29. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 6. Using a transmission jack, support the transmission and remove the bell housing bolts.

30. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 7. A view of the bell housing and throwout bearing as the transmission assembly is removed from the engine.

31. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 8. Removing the fasteners holding the pressure plate to the flywheel.

32. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 9. Removing the pressure plate and clutch disc.

33. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 10. Using a special puller, remove the pilot bearing.

34. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 11. The flywheel is being removed to be refinished or replaced as needed.

35. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 12. With the flywheel removed, check to see if the rear main seal is leaking and replace if needed.

36. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 13. Installing a reconditioned flywheel and torquing new bolts to factory specifications.

37. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 14. Installing a new pilot bearing and lubricate as per instructions in service information.

38. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 15. Using a pilot tool to align the clutch disc with the pilot bearing through the center opening of the pressure plate.

39. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 16. Installing the transmission assembly with a new throwout bearing.

40. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 17. Bleeding the air from the hydraulic clutch circuit.

41. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Rear-Wheel Drive 18. Finish the clutch replacement by reinstalling all components removed and check for proper operation.

42. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 1. The first step in almost all major service work is to disconnect the negative battery cable from the battery.

43. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 2. A new clutch kit, including the pressure plate, release bearing, and clutch disc, was purchased making sure that all of the needed information was compiled before ordering to help insure that the correct parts were purchased.

44. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 3. A holding fixture was attached to support the engine when the transaxle was removed from underneath the vehicle.

45. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 4. The “K” (lower support) member was removed to get access to the transaxle.

46. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 5. Both drive axle shafts (half shafts) were removed.

47. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 6. The transaxle is supported by a transmission jack as it is being removed from underneath the vehicle.

48. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 7. The transaxle assembly is lowered from underneath the vehicle.

49. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 8. The original pressure plate shows normal wear. The problem with this clutch was a leaking slave cylinder/ release bearing assembly.

50. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 9. The new slave cylinder/release bearing assembly is being installed.

51. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 10. The pressure plate is being removed from the flywheel.

52. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 11. The flywheel is cleaned using an abrasive pad to remove the glaze on the surface

53. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 12. The flywheel was thoroughly cleaned after being cleaned.

54. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 13. The spline grease that was included with the clutch kit is being applied to the splines of the clutch disc.

55. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 14. The pressure plate retaining bolts are torqued to factory specification while an assistant uses a pry bar to keep the flywheel from turning.

56. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 15. The transaxle is then reinstalled from underneath the vehicle.

57. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 16. The engine and transaxle mounts are reattached and the half shafts reinstalled.

58. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 17. The hydraulic clutch master cylinder is filled with DOT3 brake fluid and allowed to gravity bleed.

59. Manual Drivetrains and Axles, 7e James D. Halderman | Tom Birch Copyright © 2015 by Pearson Education, Inc. All Rights Reserved Clutch Replacement—Front-Wheel Drive 18. All fasteners were torqued to factory specification and the vehicle was test driven to confirm proper operation.