MBEYA UNIVERSITY OF SCIENCE AND

TECHNOLOGY
AUTOMOTIVE TECHNOLOGY III
ME 6203

Mr. Mbawala, SB

Mechanical And Industrial Engineering

Department
 ASSESSMENT METHODS
The course will be assessed by continuous assessment (CA) and End of semester examination
1. Continuous Assessment (50%)
Practical 30%
Theory 20%
• Test 1-10%
• Individual Assign-5%
• Group Assgn-5%
2. Semester Examination (50%)
Lecture 1; Clutch
 What to be Learned
• Define Clutch
• Classification of clutches
• Identify components of clutch
• Describe how clutch works
• Describe maintenance procedure of different types of clutches
• Perform maintenance of different types of clutches
 Introduction
A clutch is a machine member used to connect a driving shaft to a driven
shaft so that the driven shaft may be started or stopped at will, without
stopping the driving shaft
Clutch is used in manual transmission system in a vehicle, or the working
parts of any machine. e.g. fan clutch
The engagement and disengagement of the shafts is obtained by means of
a clutch
 Types of Clutch

There are two main types of clutches commonly used in

engineering practice :

a. Positive clutches
b. Friction clutches
 Types of Clutch
a. Positive Clutches
The positive clutches are used when a positive drive is
required (no slip).
The simplest type of a positive clutch is a jaw or claw clutch.
The jaw clutch permits one shaft to drive another through a
direct contact of interlocking jaws or teeth
 Types of Clutch
Positive Clutches cont..
Jaw clutch consists of two halves; one of them permanently fastened to the
driver shaft.
The other half is movable and is attached to the driven shaft.
It can freely slide axially on the shaft, but cannot turn due to feather key.
They can transmit power in both directions; they are used when it is not
necessary to engage or disengage under load.
 Types of Clutch
Advantages of positive clutch
i. They do not slip
ii. They can transmit large torque
iii. Develop no heat during engagement and disengagement because of rigid
interlocking (no friction).
 Types of Clutch
Disadvantages of positive clutch
i. Engagement of clutch cannot be possible at high speed
ii. While starting some relative motion may be required to engage.
 Types of Clutch
b. Friction Clutches
A friction clutch has its principal application in the transmission
of power of shafts and machines which must be started and
stopped frequently.
Its application is also found in cases in which power is to be
delivered to machines partially or fully loaded.
 Types of Friction Clutches
Though there are many types of friction clutches, yet the
following are important from the subject point of view :
1. Disc or plate clutches (single disc or multiple disc clutch),
2. Cone clutches, and
3. Centrifugal clutches
We will concentrate on disc(plate) clutch
 Disc clutches (single disc or multiple disc)

The clutch assembly is located between the engine and the transmission or
transaxle. The purpose and function of a clutch include the following:
• To connect and transmit engine torque to the transmission/transaxle
• To disconnect the engine from the transmission/transaxle to permit the
engine to remain running when the vehicle is stopped and to permit the
transmission/transaxle to be shifted
• To dampen and absorb engine impulses and drive train vibrations
• To provide a smooth engagement and disengagement between the engine
and the transmission/transaxle
 Components of Clutch System

The main components of clutch System

• Flywheel
• Clutch plate
• Pressure plate
• Release mechanism
1. Flywheel
The engine flywheel serves four basic purposes:
• Smoothens out or dampens engine power pulses
• Provides the connection point for the starter motor to crank the
engine
• Provides the application surface for the clutch friction disc
• Absorbs some of the heat created by clutch operation
2. Clutch plate
The clutch disc/plate is round with a splined center hole that slips over the splines
of the input shaft of the transmission/ transaxle.
Clutch plate transmit power from flywheel to input shaft of gearbox through
friction materials which riveted to both sides of the clutch disc (one side touches
the flywheel of the engine and the other side touches the friction surface of the
pressure plate).
Friction materials operate in high heat and pressure.
For many years, asbestos was the most common material used in both clutch
and brake linings.
However, it is no longer used because inhaling tiny particles of asbestos causes
lung damage.
Today, clutch friction material may contain paper, cotton, and bits of copper or
brass wire with resin holding the mixture together.
CAUTION: Always take precautions when working around clutch lining
material and assume that it contains asbestos.
3. Pressure plate
The purpose of the pressure plate is to exert a force on the clutch disc so that
engine torque can be transmitted from the engine to the transmission/transaxle.
Pressure plate is bolted to the back of the flywheel, and the clutch disc is
sandwiched in between the flywheel and the pressure plate.
The assembly consists of the pressure plate cover, face, springs, and
sometimes release levers
Since the pressure plate assembly is bolted to the flywheel, it rotates at all times.
But the clutch disc only rotates when the clutch is engaged.
3. Pressure plate cont..
• Pressure Plate Cover
The cover houses the components of the pressure plate assembly and holds them together. It provides the
means to bolt the assembly to the flywheel.
• Pressure Plate Face
Like the flywheel, the pressure plate face is usually made of iron, and the friction surface is precision
machined. The pressure plate springs are seated or attached to the back of the face. The pressure plate face
moves back and forth inside the cover as the clutch pedal is operated.
• Pressure Plate Springs
There are two main types of pressure plate spring systems:
a. Coil spring
b. Diaphragm spring.
 a. Coil spring style

This style of pressure plate uses coil springs and three or four release arms. A coil-spring-style
pressure plate is also called the lever style because it uses levers to compress the coil spring
Operation of a coil spring pressure plate is similar to a diaphragm spring pressure plate, but it has a
few additional parts.
Instead of one large spring, this type has a number of smaller coil springs placed around the back
of the pressure plate face.
The release bearing does not act directly on the springs, but rather on release levers that pivot and
push or pull the pressure plate face away from the clutch disc and flywheel.
Coil spring pressure plates are better suited than the diaphragm type for heavier-duty applications.
 b. Diaphragm spring style
Diaphragm spring is a round, dish-shaped spring with numerous segments radiating towards
the center.
The spring action is similar to that of an old-style. A release bearing, actuated by the clutch
pedal, acts directly on the inner ends of the spring, overcoming the spring tension that engages
the clutch, this action disengages the clutch.
Diaphragm springs require less force from the release bearing to disengage the clutch, they
use less space, and the assembly is lighter and more easily balanced than the other main type
of pressure plate (coil spring)
The driver must push harder on the clutch pedal to disengage a coil spring clutch than to
disengage a comparable diaphragm spring design.
The diaphragm clutch has replaced the coil spring type because the diaphragm
type has the following advantages:
● It is not affected by high speeds (coil springs can be thrown outwards)
● The low pedal force makes for easy operation
● It is light and compact i.e. few components and less space
● The clamping force increases or at least remains constant as the friction lining on
the plate wears
4. Release mechanism
It involves
i. Clutch pedal
ii. Mechanical linkage/Cable/Hydraulic circuit
iii. Release fork
iv. Release bearing
i. Clutch pedal
The clutch pedal is located on the floor to the left of the brake pedal.
When pressed, clutch disengages which eliminates the transmission of
power from the engine to the transmission and when released, clutch
engages and transmit power from the engine to the transmission.
Return springs are used to help bring the release mechanism and
clutch pedal home to their normal positions when the clutch is
engaged.
ii. Mechanical linkage/Cable/Hydraulic circuit
These are the ways in which clutch pedal movement is transmitted
to the clutch release fork
• Mechanical Linkage
This method uses a system of levers and rods to disengage the
clutch.
Many different arrangements have been used. Mechanical linkage is
mainly found on some older vehicles.
•Cable
A steel cable attached to the clutch pedal moves back and forth inside a flexible housing as the
clutch pedal is operated.
The housing is mounted in a stationary position.
It usually has a threaded sleeve on one end to allow the lengthening and shortening of the cable
for clutch adjustment.
Some cable release systems are self-adjusting, using a ratcheting mechanism on the clutch pedal
to take up slack as the clutch disc wears.
The cable release system is inexpensive and simple in design and operation, but it is more prone
to wear and binding than other types. It is always used in motor cycle
• Hydraulic Circuit
The hydraulic clutch release system uses a clutch cylinder (also called a
clutch master cylinder), a hydraulic line, and a slave cylinder(release
cylinder) to transfer clutch pedal motion to the clutch fork.
The hydraulic system is very much like a brake hydraulic system, and clutch
systems commonly use brake fluid as well
A fluid reservoir may be built into the unit, or there may be a separate
reservoir remotely mounted above the unit for easier access.
Hydraulic Circuit cont..
The master cylinder is like a single-circuit brake master cylinder.
The hydraulic line consists of metal tubing and rubber hoses, just like a
brake system.
It runs from the clutch cylinder to the slave cylinder.
The slave cylinder is mounted on the bell housing near the clutch fork.
It is much like a wheel cylinder on a drum brake with one piston and
actuating pin.
iii. Clutch fork
This is also part of the clutch release mechanism. Also called a release arm,
release fork or throw-out lever.
Clutch fork transmits movement from the external parts of the release
mechanism to the release bearing.
The fork extends through a hole in the clutch housing to reach the external
parts of the release mechanism.
A protective rubber boot fits in the hole to prevent contaminants and debris
from entering the clutch housing.
iv. Release bearing
The throw-out (release) bearing is attached to the clutch fork and rides on the fingers of
the pressure plate.
The clutch operating system moves the clutch release bearing when the driver presses
or releases the clutch pedal.
The release bearing presses against the diaphragm spring fingers or coil spring levers.
This takes spring force off the pressure plate so that it no longer clamps the friction
disc against the flywheel.
iv. Release bearing cont..
When the release mechanism is properly adjusted, there is a small clearance gap
between the throw-out bearing and the release levers/diaphragm spring, so the
bearing only has to spin during clutch disengagement.
This reduces wear on the bearing, and results in a small amount of free travel, or
free play at the clutch pedal.
The amount of free travel will be specified in the service information, usually about
an inch. However, some vehicles with "self-adjusting" clutch engagement
mechanisms use a special bearing that is designed to remain in contact with the
pressure plate at all times
Other parts in the system are
Pilot bearing
Bell housing
Clutch safety switch
• Pilot Bearing
The pilot bearing or bushing fits into the center of the
crankshaft, usually with a light press fit.
It supports the input shaft of the transmission and keeps it from
moving off center.
This is especially important when engaging the clutch.
• Clutch Housing
The clutch housing is also called the bell housing, and it encloses the clutch assembly.
It bolts to the back of the engine, and the manual transmission is bolted to the back of it.
On some vehicles, the clutch housing is part of the transmission case.
• Clutch Start Switch
Modern vehicles have a Clutch Start Switch that prevents cranking the engine with the
transmission in gear unless the clutch pedal is depressed.
This is a safety feature designed to prevent the vehicle from lurching or the engine from
suddenly starting if the starter motor is operated while the clutch is engaged and the
transmission is in gear. The switch is part of the ignition/starter circuit.
 How Clutch Works
Clutch operates on the principle of friction
When two surfaces are brought in contact and are held against each other
due to friction between them, they can be used to transmit power.
If one is rotated, then other also rotates.
One surface is connected to source of power and other to the one receives
the power.
Thus, clutch is nothing but a combination of two friction surfaces.
 How Clutch Works cont..

When the driver depresses the clutch pedal, a throw-out bearing is forced against
the fingers of the pressure plate.
When force is exerted on the center of the pressure plate, the pressure is released
from the clutch disc that has been forced against the engine flywheel.
With the pressure removed from the clutch disc, the engine can be operated without
transferring torque to the transmission/transaxle.
 How Clutch Works
This also permits the transmission/transaxle to be shifted because a shift cannot be
made if the transmission/transaxle is transferring engine torque.
When the driver reduces force on the clutch pedal, the pedal return spring and the
pressure plate spring combine to return the clutch pedal to its at-rest position.
When the clutch pedal moves up, the pressure on the throw-out bearing is released
and the force against the pressure plate spring(s) is released allowing the force of the
pressure plate to clamp the clutch disc tightly between the flywheel and the pressure
plate allowing the torque to be transmitted from engine to gear box as before.
 Clutch Troubleshooting
An automotive clutch normally provides dependable service for thousands of miles.
However, stop and go traffic will wear out a clutch quicker than highway driving.
Every time a clutch is engaged, the clutch disc and other components are subjected to
considerable heat, friction, and wear
Driver abuse commonly causes premature clutch troubles. For instance, "riding the
clutch," resting your foot on the clutch pedal while driving, and other driving errors can
cause early clutch failure
 Clutch Troubleshooting
Perform drive test by
• Checking the action of the clutch pedal
• listen for unusual noises
• Feel for clutch pedal vibrations
Gather as much information as you can on the operation of the clutch.
Use these information's, your knowledge of clutch principles and a service manual
troubleshooting chart to determine which components are faulty
 Clutch Troubleshooting
The following are the clutch problems
• Clutch Slipping
• Clutch Grabbing
• Clutch Dragging
• Abnormal noises
• Vibrations
It is important to know the symptoms produced by these problems and the parts that might be
causing them
 Clutch Troubleshooting

• Clutch Slipping
Slipping occurs when the driven disc fails to rotate at the
same speed as the driving members when the clutch is
fully engaged
This condition results whenever the clutch pressure plate
fails to hold the disc tight against the face of the flywheel
 Clutch Troubleshooting
Clutch Slipping cont..
Causes of clutch slipping
• Oil or grease on the friction linings
• Friction linings worn out
• Scored faces on the flywheel or pressure plate
• A broken engine mount
• Lack of free play at the clutch pedal
• Insufficient clamping force
 Clutch Troubleshooting
NOTE
The term clutch slipping should not, of course, be confused with
slipping the clutch, since slipping the clutch is determined by
driver control.
The ability of a friction clutch to slip before full engagement is a
decided advantage, because it allows shock-free connection to be
made between the engine and gearbox
 Clutch Troubleshooting
• Clutch Grabbing
When alternating torques occur in the slip phase (e.g., due to friction value
fluctuations) and causes vibrations of the driveline, this is called clutch grab.
Instead of slipping evenly, the clutch grips suddenly, then loses contact.
A grabbing clutch will produce a very severe vibration or jerking motion when the
vehicle is accelerated from a standstill.
Even when the driver slowly releases the clutch pedal, it will seem like the clutch
pedal is being pumped rapidly up and down.
 Clutch Troubleshooting
• Clutch Grabbing cont..
Causes of Clutch Grabbing
• Oil or grease on the disc facings
• Loose transmission mounts and worn engine mounts
• Loose disc facings
• Broken parts in the clutch, such as broken disc facings, broken facing springs,
or a broken pressure plate, will also cause grabbing .
 Clutch Troubleshooting
• Clutch Dragging
This type of clutch complaint(problem) will always become evident when
changing gear.
It has the effect of making gear engagement both difficult and noisy, because
the center plate continues to be dragged round even though the clutch pedal
is fully depressed for disengagement
 Clutch Troubleshooting
Clutch Dragging cont..
Causes of Clutch Dragging
• Clutch linings are cracked or buckled
• Clutch plate seized on the gearbox input shaft splines
• Release bearing defective
• Insufficiently effective pedal travel (excessive ‘free’ movement on the pedal or slave cylinder push
rod)
• Rusted or damaged transmission input shaft
• Hydraulic system defective (due usually to then loss of most if not all of the hydraulic oil)
 Factors that can reduce the service life of the clutch are:

• Extensive stop-and-go city driving

• Frequent severe duty, such as towing or hauling
• Contamination (such as oil leaking from the engine or
transmission)
• Driver misuse or abuse
 Check for
• Clutch Pedal Adjustment
Clutch Pedal Height
Clutch Pedal Free Play
• Clutch remove and installation
THANKS