Clutch Course

Question 1

Course Objectives

Answer 1

Identify clutch components

Question 2

Course Objectives

Answer 2

Demonstrate the inspection clutch components

Question 3

Course Objectives

Answer 3

Explain the operation of clutch components

Question 4

Course Objectives

Answer 4

Describe in-vehicle and out-of-vehicle resetting process

Question 5

Course Objectives

Answer 5

Diagnose clutch and transmission system

Question 6

Component Identification

Answer 6

Intermediate plate

Question 7

Component Identification

Answer 7

Driven discs (front & rear)

Question 8

Component Identification

Answer 8

Flywheel

Question 9

Component Identification

Answer 9

Clutch cover and release bearing

Question 10

Component Identification

Answer 10

Pilot bearing

Question 11

Component Identification

Answer 11

Clutch brake

Question 12

Hydraulic control system

Answer 12

Clutch Cover (pressure plate) & release bearing assembly

Constructed of either stamped steel or cast iron and will be bolted to the flywheel. Contains the pressure plate, which is fitted to the cover with pressure springs. Contains the release bearing and levers, which move the pressure plate back and forth, thereby making or breaking contact with the disc assembly.

Question 13

Interference Fit Technology

Answer 13

An interference fit, also known as a press fit or friction fit is a fastening between two parts which is achieved by friction after the parts are pushed together, rather than by any other means of fastening

Question 14

Transmission input shaft

Answer 14

Rotating shaft that receives power from the power source and introduces it into a mechanical system

Question 15

Rear main seal

Answer 15

Rear main seals are not to be replaced due to clutch replacement

non leaking rear main seals, once replaced, have a higher chance of leaking due to replacement.

Question 16

Flywheel

Answer 16

Flywheel runout spec is .008

Pilot bearing bore runout is .005. Flywheel housing ID runout is .008. Flywheel housing face runout is .008. Depth of scores or cracks limited to .040. Check with OE for min. thickness spec. Inspect for excessive gouges, smoothness, hot spots & heat cracks. Resurfacing guidelines. Use good judgement when deciding to send out a flywheel for machining and seek advice from shop manager if you have -estons.

Question 17

Flywheel housing ID run out

Answer 17

Secure dial indicator base to crankshaft

Put gauge finger against flywheel housing Id. Rotate flywheel one revolution. Max runout is .008

Question 18

Clutch Primary Purpose

Answer 18

Clutch secondary purpose

Transfer power from engine/flywheel to transmission. Following is how that happens: At the point where the clutch engagement begins (clutch pedal partially released), the transmission shaft may be stationary, as when vehicle is not moving, or it may be rotating at a different speed than the flywheel, as in the case of up-shifting. Once the clutch is fully engaged (clutch pedal fully released), both the engine flywheel and the transmission input shaft will rotate at the same speed. Dampen unwanted vibrations that normally exist in the driveline system. Following is how that happens. The driven disc springs provide a flexible link between the friction surface and the disc hubs. Dampened clutch discs are specifically designed to prolong life of the drivetrain components by the reduction of vibration from the engine, non-uniform u-joint angles, and road dips/bumps.

Question 19

Driven Discs

Answer 19

Intermediate plate

Driven by the clutch cover(commonly referred to as the pressure plate) or by the flywheel on certain clutch designs. Increases the torque capacity of the clutch by providing additional surface area for facing material.

Question 20

Pilot Bearing

Answer 20

Contain dampers to reduce critical vibrations in today’s electronic, high horsepower engines. The proper selection of springs depends on factors such as engine, flywheel and transmission selected in truck. Contain facing material which are critical to performance as they receive the torque delivered by the engine every time the clutch is engaged. Driven disc ceramic facings have greater heat tolerance and torque capacity than organic facings. They engage quicker, reduce slip and deliver longer life. Organic facings are a non-asbestos facing that are adequate for low horsepower, on highway applications.

Question 21

Pilot Bearing

Answer 21

Connects the manual transmission input shaft to the engine crankshaft. Allows the input shaft to rotate independently of the crankshaft. Should be replaced whenever the clutch assembly is replaced. Failure to use a clutch aligning tool can result in damage to the pilot bearing upon re-installation of the transmission

Question 22

Pilot Bearing cont.

Answer 22

Pilot bearings when pressed in flywheel are an interference fit design

Question 23

Sealed for life

Answer 23

Require no lube

Question 24

Clutch Brake

Answer 24

Hydraulic Control System

Located between the release bearing housing and transmission front bearing retaining cap. Engaged by tangs to the transmission input shaft. Only use one piece brake if transmission is removed. Consists of a pedal unit and a slave cylinder, connected by a hydraulic hose and fastened with a quick disconnect clip. Pedal unit includes a hydraulic subassembly, composed of the master cylinder and reservoir, which can be removed from the pedal unit for service purposes.

Question 25

Input bearing retainer

Answer 25

Inspection

Retains input shaft bearing. Provides friction surface for clutch brake. Following section covers key inspection of clutch components. Reminder- Any time a component shows wear such as hot spots, grooves or abuse, it should be replaced with a

Question 26

What does the pedal unit include?

Answer 26

A hydraulic subassembly, composed of the master cylinder and reservoir, which can be removed from the pedal unit for service purposes.

Following section covers key inspection of clutch components.

Question 27

What is the fluid level reminder for?

Answer 27

To check the fluid level in transmissions each time lines are removed, the radiator is replaced, or an accident repair is performed.

Take the time and make sure we get it right the first time, every time.

Question 28

What should be checked for when inspecting the clutch?

Answer 28

Hot spots caused by clutch slippage, cracks (heat), and damper springs for fit to cavity.

Reminder- Any time a component shows wear such as hot spots, grooves or abuse, it should be replaced with a new OE part.

Question 29

What is the max runout for flywheel face?

Answer 29

.008

Secure dial base to flywheel housing face. Put gauge finger in contact with the flywheel face near outer edge. Rotate flywheel one revolution.

Question 30

What should be done after replacing the clutch cover, release & pilot bearing?

Answer 30

Ensure smooth operation of new bearing after installation, listen for abnormal noise when clutch is depressed, and check for any hard shift complaints.

Transmission input shaft continues to spin slowly when the pedal is depressed and causes clutch drag