Manual Drivetrains and Axles

Fourth Edition

Tom Birch
and

Chuck Rockwood

Chapter 4
Clutch Theory
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The clutch smoothly transfers power from the engine to the transmission. The major parts are: the disc

the pressure plate assembly, and

the release bearing and linkage.

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood

2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

When the clutch is applied, springs squeeze the disc between the pressure plate and flywheel (top half). When the clutch is released, the release bearing and pressure plate levers pull the pressure plate away from the disc (bottom).

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood

2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Animation: Clutch Operation PC MAC

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The amount of torque that a clutch can transfer is determined by:

The linings coefficient of friction The clamping pressure from the pressure plate The diameter of the disc and pressure plate The number of friction surfaces

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood

2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

A clutch disc has two lining sections that are riveted to the marcel.

The marcel is attached to the damper springs and hub.

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood

2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The damper springs are designed to reduce crankshaft torsional vibrations that can produce transmission gear rattle.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The marcel expands the disc when it is released.

The marcel compresses as the clutch applies to give a slight slippage and smoother feel.

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood

2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

A typical disc.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The three major types of pressure plate assemblies are the:

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood

2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

An exploded view of a diaphragm style shows the cover (1), diaphragm spring (3), pressure plate (7), pivot ring (14), and torque straps (12).
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

An exploded view of a Borg and Beck style shows the cover (1), coil springs (3), release levers (5), pressure plate (7), and pivot stands (10).
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Most pressure plates are of the push-type. The release bearing pushes on the release levers or diaphragm spring to release the clutch.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

A pull-type clutch has the release bearing pulling the diaphragm spring toward the transmission to release the clutch.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

FIG 4.20 HERE

Some vehicles use a stepped flywheel with a very thick rim. Note the pilot bearing supporting the transmission input shaft; pilot bearings are not used with many transaxles.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

A double disc clutch doubles the clutch torque capacity. The floater plate between the two discs is driven by the clutch cover.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The release/throw out bearing is (4) forced against the pressure plate by the clutch fork (3). This fork pivots on the pivot ball (2) and is moved by a hydraulic slave cylinder (5).
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

There is a variety of release bearings.

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Most older vehicles use mechanical clutch linkage.

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Some vehicles use a flexible cable and housing between the clutch pedal and fork.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

A self adjusting mechanism (the gear quadrant, pawl and tension spring) keep this cable clutch linkage properly adjusted.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The hydraulic clutch linkage reservoir, master cylinder, and slave cylinder are connected by metal and plastic lines. Note the release bearing and concentric slave cylinder.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

The master cylinder forces fluid through the line to the slave cylinder which moves the clutch fork to release the clutch.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Animation: Clutch Hydraulics PC MAC

Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Many clutch pedals have a switch that allows the starter to operate only when the clutch pedal is pushed down.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Many clutch pedals have a switch that allows the starter to operate only when the clutch pedal is pushed down.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Many clutch pedals have a switch that allows the starter to operate only when the clutch pedal is pushed down.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458

Some vehicles use a dual mass flywheel. Long damper springs drive the heavier, secondary flywheel to remove most crankshaft torsional vibrations.
Manual Drivetrains and Axles, 5e By Tom Birch and Chuck Rockwood 2008 Pearson Education, Inc. Pearson Prentice Hall Upper Saddle River, NJ 07458