TRANSMISSION SYSTEM

This is a general term to describe all the components required to transmit

power from the engine to the wheels.

ARANGEMENT OF COMPONENTS ACCORDING TO DRIVE ARRANGEMENT

FRONT ENGINE FRONT WHEEL DRIVE FRONT ENGINE REAR WHEEL DRIVE
Clutch Clutch
Gearbox Gearbox
Final drive Propellershaft
Differential Final drive
Driveshaft Differential
Halfshaft

CLUTCH
This is one of major vehicle systems found on motor vehicle with manual
transmission. It is found between engine and gearbox. When the driver wants to shift
gears, depresses the foot operated clutch pedal

When the driver pushes the pedal down, the clutch disconnects drive from the
engine to the gearbox meaning engine power cannot flow to the gearbox. When the
pedal is released the clutch engages drive and allows power to flow from the engine
to the gearbox. Parts in clutch may be damaged by trying to shift while the engine is
transmitting power to the gearbox.

Purpose:
It connects and disconnects drive from the engine to the gearbox.

Functions:
1. It allows engine cranking and permits the engine to run freely without
delivering power to the transmission or it provides temporary neutral position.
2. It permits the driver to shift the transmission into various gears
3. It allows smooth take off of drive from rest and lessens the shocks on gears,
shafts and other drive train parts.

TYPES OF CLUTCHES
There are various types of clutches depending on how they allow power to be
transmitted from one member to the other. These types are:
 dog clutch
 and friction clutch.
Dog clutches:
It uses dog teeth to engage drive between two members in contact and is commonly
used in manual gearboxes. During drive transmission it leads to jolting of the
gearbox resulting in excessive wear of the gears and noise.

Dog teeth
Friction clutch:
This type of clutch depends on friction between two members in contact to transmit
drive. It is categorised into two types:
 Dry friction clutch and
 wet friction clutch.

Dry clutch:
 Its surfaces do not have any presence of liquid and is commonly used in
vehicles with manual gearbox.
Wet clutch:
 Between its surfaces in contact there is presence of fluid. And is commonly
used in vehicles with automatic gearbox.

DESIGNS OF CLUTCHES
The way clutch is constructed it gives two designs of clutch depending on the kind of
transmission found on the motor vehicle (manual or automatic transmission). These
designs are:
 single plate clutch
 and multi plate clutch.

Single plate clutch

This is a typical clutch which consists of three basic parts engine flywheel, clutch
plate and pressure plate. The flywheel and pressure plate are the driving members
since they are attached to and rotate with the engine crankshaft and clutch is a
driven member.
Flywheel
It gives the following functions;
• It temporarily stores energy during power stroke and releases it during idling
strokes
• It provides a mounting point for the starter ring gear
• It provides one mating drive surface for the clutch plate

Clutch plate
It is also called driven plate/friction plate. It consists of the following main parts:
 splined central hub and plate
 cushion springs
 dampening springs
 and friction facings.

Functions:
1. Clutch plate connects and disconnects drive from the engine to the gearbox
by sliding back and forth on the shaft splines.
2. It also allows the drive to be taken up gradually and smoothly as the vehicle
moves off from rest by using the cushion springs between the friction facings.
When the clutch engages, the cushions spring compresses slightly to take up
the shock of engagement.
3. The dampening springs help to reduce the torsional vibrations caused by the
engine power impulses.
Grooves on both sides of the friction disc prevent the facings from sticking to the
flywheel face and pressure plate when the clutch disengages and cool the facings.
The grooves break any vacuum that might form and cause the facings to stick.
 Friction facings/linings
Properties of the friction linings/facings
1. Stable frictional qualities over a wide range of operating

Types of clutch plates:

 Rigid hub clutch plate
 Spring hub clutch plate

The clutch is made of asbestos because of its high coefficient of friction. At the same
time it’s hazardous hence other vehicle manufactures have replaced it with ceramic
metallic faces.

Pressure plate
It provides a necessary clamping force for the driven plate. It is categorised into two
types depending on the type of springs used to provide the clamping force.
These are;
Diaphragm spring pressure plate and coil spring pressure plate.
Coil-spring pressure plate
It consists of the following main parts pressure plate cover, coil springs and disc. The
clamping force is provided by several coil springs placed around between the cover
and the pressure plate disc.

Diaphragm-spring pressure plate

The clamping force is provided by the diaphragm springs which have tapered fingers
pointing inward from a solid ring.
Operation of single plate clutch
When the driver depresses the clutch pedal, the pressure plate moves away from the
friction disc hence; disconnecting drive from the engine to the gearbox. Releasing
the clutch pedal makes the pressure plate springs to clamp the clutch plate between
the engine flywheel and pressure plate disc engaging the drive from engine to the
gearbox.
Multi-plate clutch design

It is made up of more than one friction plate and the type of friction plates commonly
used are wet clutches. They are normally used where large amounts of power/torque
are to be transmitted. In addition, they are used in confined spaces where maximum
diameters of friction plates are limited such as automatic gearboxes.

CLUTCH LINKAGES
There are several parts that connect the clutch pedal to the pressure plate making
up a clutch linkage. It can either be
 mechanical,
 hydraulic and
 electronical

Mechanical clutch linkage

Operation
When the driver depresses the clutch pedal, the cable pulls the clutch fork which
moves the release bearing towards the pressure plate springs. This withdraws the
pressure plate from the clutch plate hence, disengaging drive because the clutch
plate becomes free. Releasing the clutch pedal, the cable relaxes and makes the
release bearing to move away from the pressure plate springs. The spring exerts
force on the clutch plate and engages drive.

Hydraulic clutch linkage

This linkage is used when the clutch location makes it difficult to put mechanical
linkage. It is also used in high- performance engines because of its efficiency
compared to mechanical linkage. It consists of the following main parts; clutch
master cylinder, flexible pipes and slave cylinder (servo).
ELECTRONICALLY CONTROLLED CLUTCH
This is a hydraulically operated clutch that is electronically controlled. No clutch
pedal is needed. Sensors send information about the operation of the
 throttle
 clutch and
 transmission to an Electronic Control Unit (ECU)

When the driver moves the gearshift lever, the ECU then signals the hydraulic power
pack. It controls the fluid pressure in the hydraulic cylinder to engage or disengage
the clutch. This disengages quickly and remains disengaged until the driver releases
the gearshift lever. There are other types of automatic clutches. They all disengage
when the control unit sends the proper signals to an electric, hydraulic, pneumatic or
vacuum actuator. The car may or may not have a clutch pedal.

REALESE BEARING
The release bearing moves when the driver depresses the clutch pedal. The bearing
travel pushes or pulls the release levers or fingers inward or outward to disengage
the clutch. Most of the release bearings are ball bearing type, but they vary in
construction and operation.

Types of release bearings in terms of construction

 graphite
 carbon impregnated

CLUTCH SAFETY SWITCH

It is also called a Starter- clutch interlock switch. It prevents cranking if the engine is
engaged. The clutch pedal must be depressed or the engine will not crank when the
ignition key is turned to start. The movement of the clutch pedal closes the safety
switch. This completes the electrical circuit to the starting motor.

Clutch faults
Many troubles can develop in the clutch, producing different conditions and
complaints from the driver. The chart below lists common clutch faults, possible
causes and corrections.

CLUTCH FAULTS POSSIBLE CAUSES CORRECTION

Clutch slip while Broken or weak pressure Replace
engaged plate springs
Binding in clutch linkage Free, adjust, lubricate
Broken engine mount Replace
Worn friction disc facings Replace disc
Incorrect clutch- linkage Adjust
adjustment
Grease or oil on disc facings Replace disc

Warped friction disc Replace

 Incorrectly adjusted release Adjust
levers
Clutch chatters/grabs Binding in clutch linkage Free, adjust, lubricate
while engaging Broken engine mount Replace
Grease or oil on disc facings Replace disc
or
glazed or loose facings
Binding of friction- disc hub Clean and lubricate
on splines
Input shaft
Warped friction disc Replace
Clutch drag/spins Incorrect linkage adjustment Adjust, repair or replace
while disengaged or
operation
Warped friction disc or Replace
pressure plate
Loose friction disc Replace
Facings
Improper release lever Adjust
adjustment
Friction -disc hub binding on Clean and lubricate splines,
input shaft replace defective parts.

Clutch noisy while engaged Friction -disc hub loose on Replace

input shaft

Friction –disc damper springs Replace

broken or week

Misalignment of engine and Align

transmission
Clutch noisy while Release bearing worn, Replace
disengaged binding, or out lubricant

Release levers not properly Adjust or replace pressure

adjusted plate assembly

Pilot bearing in crankshaft Replace

worn or out of lubricant

Diaphragm spring worn or Replace pressure plate

Damaged assembly

Clutch pedal pulsates Engine and transmission not Align

aligned.

Flywheel not seated on Seat properly. Straighten,

 crankshaft flange or flywheel replace flywheel.
bent.

Clutch housing distorted Replace

Release levers not evenly Adjust or replace

adjusted.

Warped pressure plate or Replace

friction disc.

Pressure plate assembly Align

misaligned.
Broken diaphragm spring Replace pressure plate
Assembly

Identifying clutch system bearing noise:

 checking transmission- input shaft bearing
 parking brake on
 gearshift lever in neutral
 engine start
 release the clutch pedal if you had to depress it for engine cranking
Any bearing noise you can hear is from defective transmission input shaft bearing since it’s
the only bearing turning.

 Checking release bearing

 Engine idling
 Gear lever neutral
 Depress clutch pedal to the end of its free play
 Defective release bearing will start making noise
 Checking pilot bearing or bushing
 Engine idling
 Gearshift lever in neutral
 Push clutch pedal to the floor
 Any noise occur is from pilot bearing or bushing

CLUTCH SERVICE
Checking clutch pedal free play:
This is the distance the pedal moves before the release bearing contacts the pressure plate
fingers or levers. The free play may increase or decrease as the frictional disc and other parts
wear or the cable stretches.

To check pedal free play:

 Depress the pedal with your hand until the pedal force is required, means you have
reached the end of freeplay.
 In most cars the freeplay is about 25mm.
 Turn the adjusting nut to get the proper freeplay
  On some cars with self-adjusting linkage, raising the clutch pedal with your hand
causes the linkage to self- adjust.

NOTE: The clutch pedal height must be checked and adjusted before adjusting the freeplay.
Clutch pedal height is the distance from the top of the clutch pedal to the floor.

BLEEDING CLUTCH HYDRAULIC SYSTEM

This is the procedure that removes the air, usually by draining part of the fluid.

When do you bleed the system?

 After disconnecting any part in the hydraulic line
 If the fluid level has dropped so low that air has entered the clutch master cylinder.

PROCEDURE
1. Clean dirty and grease from around the reservoir cap
2. Remove the cap and diaphragm under it
3. Fill the reservoir to the Full mark with fresh, new fluid.
4. Use fluid specified by manufacturer( DOT 3 brake fluid)
5. Connect one end of the rubber tube to the bleed screw in the slave cylinder and
immerse the other end in a half- full transparent container.
6. Slowly pump the clutch pedal several times
7. Apply a light force to the clutch pedal and loosen the bleed screw until the fluid
discharges from the tube to the container.
8. Air bubbles are seen in the bottle
9. As the pedal sinks to the floor, close the bleed screw.
10. Repeat this procedure until no more air bubbles appear in the fluid.
11. Refill the fluid reservoir
12. Install the diaphragm and cap

CAREFUL: brake fluid softens and dissolves paint. Wash it off immediately. Never reuse
the fluid that has been bled.

CLUTCH REMOVAL
Procedure:
1. Disconnect the negative cable from the battery
2. Disconnect the clutch master pushrod from the clutch pedal
3. Disconnect the hydraulic line and remove the slave cylinder
4. Then remove the transmission from the engine
5. Clean the clutch and clutch housing
6. Examine the clutch cover and flywheel for alignment marks
7. Install a Clutch aligner into the crankshaft pilot bearing to prevent slippage and
damage to the friction disc
 Clutch aligner
8. Remove the pressure plate assembly by loosening the screws that attach the pressure
plate to the flywheel
9. Loosen each screw one turn at a time following diagonal sequence until the pressure
plate spring force is relieved
10. The remove the pressure plate assembly and friction disc

INSPECT AND SERVICING CLUTCH PARTS

1. Look for oil leaks from the engine rear main bearing oil seal and from the front of the
transmission

Checking pressure plate warpage:

Straightedge

Feeler gauge

Checking friction disc for runout:

Inspecting flywheel:
1. Flywheel ring gear for worn, chipped or cracked teeth.
2. Flywheel friction face for uniform appearance and cracks, grooves, heat checks and
uneven wear.
3. If it has worn unevenly, measure flywheel runout with dial test indicator.
4. If the surface is scored or worn, replace the flywheel
5. Install a new flywheel if resurfacing removes more than 1.14mm of metal fro
flywheel face

Inspecting the pilot bearing:

1. Turn the inner race of the bearing in its normal direction of rotation with your fingers.
2. Replace if its excessively loose, noisy, hard to turn, or fails to turn.
3. Measure its diameter with a small- hole gauge.

CLUTCH INSTALLATION
Is usually the reserve of removal.
1. Align the pressure plate mark with the flywheel
2. Install a clutch aligner in pilot bushing
3. Install attaching screws through the holes in the cover
4. Finger tight the screws, then tighten one turn one by one with a spanner to take the
pressure plate spring tension gradually and evenly.
5. Follow tightening sequence to a void warping of the pressure plate
6. Then use a torque wrench to tighten the screws to the specified torque
7. Lubricate splines on the transmission inputshaft and the front bearing retainer
extension ( use multipurpose grease)
8. Lubricate and install the release bearing
9. Remove the clutch aligner
10. Attach the transmission to the clutch housing
11. Check:
 Splines on the input shaft mesh with the splines in the friction disc hub
 The end of the input shaft seats in the pilot bearing
 Gap between the transmission housing
 Install transmission bolts
12. Bleed the hydraulic system if necessary and refill the reservoir, then check for smooth
and full clutch disengagement.