1. Teknik Kendaraan Ringan
CLUTCH
Teknik Kendaraan Ringan
Semester 3 th Class XI
Kompetensi Kejuruan
SK-KD 7TH

2. DIAGRAM ALUR PENCAPAIAN KOMPETENSI

4. Free play Clearance between T/O bearing and clutch fingers
Measured at clutch pedal
Usually 1 ½ inches of free movement
Goes away as clutch disk wears thinner
Some manufactures use T/O bearings that always ride on the clutch fingers
Usually self adjusting
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5. Clutch Linkage Can be very complicated
Have the right amount of movement and direction without too much pedal pressure
Wear
Motor mounts
Spring to pull T/O bearing away
Has to be lubricated
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6. Over-center spring Helps pull up on clutch pedal
Helps pull down on clutch pedal
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7. Checking Flywheel for Run-out
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8. Checking pressure plate for warpage
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9. Clutch Disk Replacement
Very wise to:
Have flywheel surfaced (even with no run-out or hot spots)
Replace pilot bushing or bearing
Replace T/O bearing
Replace pressure plate (cover, plate springs)
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10. Clutch Disk Replacement
Very wise to inspect & replace as necessary:
Clutch fork & pivot
Input shaft bearing retainer on transmission (where T/O bearing slides)
Linkage, cable or hydraulic components
Motor mounts
Flywheel ring gear
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11. Installing new clutch
Drive in pilot bushing or bearing with bushing driver
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12. Installing new clutch
Loctite and torque flywheel to specifications on a clean crankshaft hub
You must use clutch alignment tool (pilot shaft) when bolting up pressure plate
Torque and Loctite pressure plate to specifications
Use a crossing pattern to pull pressure plate down evenly
12/2001
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13. Universal clutch alignment tool
Select end that fits tight in pilot bushing or bearing
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14. Universal clutch alignment tool
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15. Universal clutch alignment tool
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16. Clutch Alignment tools (pilot shaft)
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17. Adjust clutch Jam nut Adjusting nut
Shorten or lengthen linkage or cable to reach proper free-play
Jam nut
Adjusting nut
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18. Basic purpose Used to trasnmits engine power to the transmission
Flywheel
Bolted to crankshaft
Provides surface for clutch disc to work on
Clutch disc
Splined to transmission input shaft
Fits between flywheel and pressure plate
Pressure plate
Bolted to flywheel
Applies squeezing pressure to disc
Acted on by throw out bearing

19. Friction disks Cushion springs Waved metal between clutch half's
Dampen clutch engagement

20. Friction disks Torsional springs Can be spring or rubber
Dampen power impulses from crankshaft
12/2001
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21. Torsional Springs Has pins to limit amount of twist.
Springs try to keep it centered between pins.
Springs sometimes get weak and start rattling or fall out
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22. Friction material isn’t very thick. Minimum thickness around .012”
Clutch disks
Friction material isn’t very thick.
Minimum thickness around .012”
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23. Flywheel

24. Flywheel Acts as engine balancer
Works with crank balancer to smooth out firing pulses
Some will be balanced to engine
Adds inertia to engine rotation
Works as heat sink for clutch
Ring gear for starter engagement
Some vehicles have dual mass flywheel

25. Flywheel service
Visually inspect for hot spots, grooves, scoring and cracks
Check with dial indicator for runout and crank end play
Most flywheels can (should) be resurfaced
Must remove dowel pins
Inspect ring gear

26. Flywheel service
Flywheel should be marked before removing to maintain balance
On Front wheel drive cars a lot of Flywheels are used for Ignition timing marks. They should be marked before removing. Some will only bolt on one way don’t take the chance MARK IT

27. Clutch disc

28. Clutch disc Friction material disc splined to input shaft
Friction material may contain ASBESTOS
Friction material can be bonded or riveted
Friction is attached to wave springs
Most have torsional dampener springs
Normal wearing component
Normally a worn out disc will cause slipping

29. Clutch disc service Inspect for wear similar to brake pads
Common to have loose or broken springs
Common failure due to oil contamination
Must find cause BEFORE repair
Normally purchased in kit containing pressure plate, disc, throw out bearing

30. Clutch disc service Clutch disc will normally have a flywheel side
Disc must be centered with clutch alignment tool before pressure plate bolted down
Make sure new disc fits on input shaft of the transmission before you install it

31. Pressure plate

32. Pressure plate Provides clamping pressure to disc
Works like spring loaded clamp
Can use bearing
Can use coil springs and levers acted on by Throw Out bearing

33. Pressure plate service
Mark relation to flywheel if reused
Remove bolts slowly in criss-cross pattern
Inspect fingers for parallelism, cracking or uneven wear
Inspect friction surface for hot spots, cracks etc and with straight edge for warpage
Must be torqued to specs and in sequence
Uses hard bolts

34. Release/ throw out bearing

35. Release/ throw out bearing
Acted on by clutch fork - acting on pressure plate
Moves toward flywheel when pedal pushed
Slides on front portion of transmission called bearing retainer
Normally not in contact with pressure plate until pedal pushed

36. Release bearing service
Very common failure - isolated by lightly applying clutch and listening
Inspect for looseness or roughness
Most are sealed but some were lubeable
Clutch fork must be lubed at pivot point and bearing contact points
Bearing retainer and input shaft should be lubed
Clutch fork must be secured at the pivot point

37. Pilot bearing / bushing
Used on some cars
Supports front of transmission input shaft
Can be needle bearing or bronze bushing
May be part of clutch kit

38. Pilot servicing Should always be changed with clutch
Can be isolated by applying clutch in gear
Special pullers may be used for removal
Can be removed with grease
Should be lightly lubed on installation

39. Clutch linkage Can be operated by cable, rods or hydraulics
May be automatic or manually adjusted
Hydraulic will have a master and slave cylinder
Will use brake fluid for hydraulic action
Will need bleeding with repairs

40. The End