Clutch diagnosis module - EAI: European Auto Importseai.net.au/CLUTCH DIAGNOSIS 01 2014 clutch...

I Clutch I Warranty diagnosis tool

Clutch diagnosis module

IntroductionIn order to give a support to his customers during warranty analysis, clutch diagnosis module.

This module includes the majority of defects which we can be detected on a clutch. These defects are due to the clutch itself, but in its environment, its assembly or its use.

They are grouped by felt then by visual observation.

How to use this diagnosis module ?1. To understand the defect felt by the customer.

2. To do a visual analysis of the part.

3. To select the corresponding index card

If no index card corresponds to the defect, we thank you for sending us the warranty form. We will analyze the issue.

DT-VT-01

2014

diagnosis tool I Information

Clutch diagnosis module

In order to give a support to his customers during warranty analysis, Valeo Service created a

This module includes the majority of defects which we can be detected on a clutch. These defects are due to the clutch itself, but in its environment, its assembly or its use.

They are grouped by felt then by visual observation.

How to use this diagnosis module ?To understand the defect felt by the customer.

If no index card corresponds to the defect, we thank you for sending us the

Summary1. Chaterring : Jerky functioning1.1 Chaterring in accelerated phase (Power train)1.2 Chattering in starting up phase (command system)1.3 Chattering - Progressive wears on the bearing1.4 Chatering - Shaken rivets1.5 Chattering - Grease centrifugation

2. Noise : A noise is felt in neutral or in every speed passag e 2.1 Noise - Presence of grease on the friction hub2.2 Noise - Deterioration of the springs shock absorbers2.3 Noise and vibrations - Breakage of the guide slice and ejection of a spring2.4 Noise- Springs clearance2.5 Slipping and noise - Blades breakage

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.1 Slipping - Descent of the pedal, hydraulic systems3.2 Slipping - Excess of grease on the bearing3.3 Slipping - Bad return in position of the bearing3.4 Slipping - Destruction of the friction3.5 Slipping - Spy seal leak3.6 Slipping - Linings pollution 3.7 Slipping and noise - Blades breakage

1.2 Chattering in starting up phase (command system)

A noise is felt in neutral or in every speed passag e

Deterioration of the springs shock absorbersBreakage of the guide slice and ejection of a spring

The car doesn't accelerate in spite of it geared up the engineDescent of the pedal, hydraulic systems

4. Bad speed changing : Speeds engage with difficulty in neutral or by driv ing 4.1 Bad speed passage and noise - Cover deformation or deterioration4.2 Bad speed changing - Parallelism defect of the diaphragm fingers4.3 Bad speed changing - Deformation of leaf strips set4.4 Bad speed changing – Flask sudden wear (Volkswagen 4.5 Bad speed changing - Hard pedal4.6 Bad speed changing - Routing and skewed of the bearing fork

Summary

4.6 Bad speed changing - Routing and skewed of the bearing fork4.7 Bad speed passage - Deterioration of the hub grooves4.8 Bad speed passage - rocking of the diaphragm

5. Impossibility of speed changing : Speeds do not engage.5.1 Impossibility of speed passing - Perforated flask ( Volkswagen car)5.2 Difficulty / Impossibility of speed changing - Deterioration of the hub grooves5.3 Impossibility of speed changing - Unsetting of the bearing sleeve5.4 Impossibility of speed changing - Destruction of the hub grooves5.5 Impossibility of speed changing - Destruction of the hub and spring ejection5.6 Impossibility of speed changing - rocking of the diaphragm5.7 Impossibility of speed changing - Breakage of the pressure plate5.8 Impossibility of speed changing - Destruction of the bearing (lack of pre5.9 Impossibility of speed changing - diaphragm broken5.10 Impossibility of speed changing - Wear of the of the positioning throat (lack of pre5.11 Impossibility of speed changing - Set of strips torn5.12 Impossibility of speed changing - Deformation of leaf strips set

6. Lexicon / Définition6.1 Clutch environment6.1 Clutch environment6.2 Clutch components'6.3 Definition of motor acyclisms

Speeds engage with difficulty in neutral or by driv ing Cover deformation or deterioration

Parallelism defect of the diaphragm fingersDeformation of leaf strips set

wear (Volkswagen vehicle)

Routing and skewed of the bearing forkRouting and skewed of the bearing forkDeterioration of the hub grooves

Speeds do not engage.Perforated flask ( Volkswagen car)

Deterioration of the hub groovesUnsetting of the bearing sleeveDestruction of the hub groovesDestruction of the hub and spring ejectionrocking of the diaphragmBreakage of the pressure plateDestruction of the bearing (lack of pre-load)diaphragm brokenWear of the of the positioning throat (lack of pre-load)Set of strips tornDeformation of leaf strips set

1. Chaterring : Jerky 1.1 Chaterring in accelerated phase (

This chatter is felt in slipping end phase and/or after slipping.Test Conditions : In 1st or reverse gear, release slowly vehicle judder occurs.Defect Origin : The chattering is probably du to a wear of the the connecting torque rod or engine dysfunction

The bad condition of the silentblocs and the rods involves the swing of the engine what amplifies this phenomenon of chattering at the time of the passage of the couple.

VALEO adviceVALEO advice•To proceed to the evaluation of the engine (ignitio n, carburetion, injection).•To check and/or change the silentblocs

y functioning1.1 Chaterring in accelerated phase (Powertrain)

This chatter is felt in slipping end phase and/or after slipping.In 1st or reverse gear, release slowly as possible the clutch pedal the

du to a wear of the silentbloc (engine, gearbox), the connecting torque rod or engine dysfunction

and the rods involves the swing of the engine what amplifies this phenomenon of chattering at the time of the passage of the

To proceed to the evaluation of the engine (ignitio n, carburetion,

silentblocs , the rods anti-tipping engine.

1. Chaterring : Jerky 1.2 Chattering in starting up phase (command system)

Test Conditions : in 1st or reverse, release the clutch pedal normally. The vehicle ahead jerk.Defect Origin : t he clutch order system is probably defective:

Cable system: t he fork and his articulation are oxidized and/or gummed , it generates a release of the clutch pedal by jerking. The

VALEO advice

a release of the clutch pedal by jerking. The clutch cable may be damaged (frayed) and generates the same feeling on the pedal.

VALEO adviceDuring the clutch installation, it is imperative to check and /or replace order organ , its fixation (bearing, axe), the guid e tube and without excess the required points.

y functioning1.2 Chattering in starting up phase (command system)

1st or reverse, release the clutch pedal normally. The vehicle ahead

clutch order system is probably defective:

Hydraulic system: t he transmitter and receiver are probably oxidized, seized, or blocked, by a leak or by the utilization of an blocked, by a leak or by the utilization of an immiscible liquid.

it is imperative to check and /or replace order organ , its fixation (bearing, axe), the guid e tube and grease

1. Chaterring : Jerky 1.3 Chattering - Progressive wears on the bearing

Test Conditions : in first or reverse gear, release the clutch pedal normally, you feel a nonprogressive torque. The vehicle move by juddering .

Defect Origin : a lack of bearing pre-load and/or eccentricity (radial movement of the bearing on the diaphragm) of the gearbox.

VALEO advice

An abnormal wear is visible on the diaphragm fingers.

VALEO adviceThe preload is generated by a spring placed around the axis of the pedal. It located on the top of the clutch pedal or if it's a adjustable cable control the spring is on the fork axis lever.

• in the case of automatic adjustment cable control, the preload spring is located on the top of the clutch pedal, o r inside the cable.

• in the case of transmitter - receiver command, the preload spring is located in the receiver behind the piston.

y functioningProgressive wears on the bearing

in first or reverse gear, release the clutch pedal normally, you feel a non-progressive torque. The vehicle move by juddering .

load and/or eccentricity (radial movement of the

An abnormal wear is visible on the diaphragm fingers.

The preload is generated by a spring placed around the axis of the clutch pedal or if it's a adjustable

the spring is on the fork axis lever.the case of automatic adjustment cable control, the preload

spring is located on the top of the clutch pedal, o r inside the

receiver command, the preload spring is located in the receiver behind the piston.

1. Chaterring : Jerky 1.4 Chatering - Shaken rivets

Test Conditions : i n first or reverse gear, release the clutch pedal normally, you feel a nonprogressive torque . The vehicle judder occurs.Defect Origin : the shock of the trimmings originates in an offsetting of the gear box or with beat of the input shaft.

VALEO adviceAt the time of the gearbox accosting, it is recomme nded to maintain the engine and the gearbox aligned by using hoist o r jack until their

This shock causes instabilities of friction which are going to reveal a ré clutch.

fixing. Take care to the conditions of the contact plan and the fixing pins.Control the alignment of the engine/gearbox and res pect the tightening torques of the screws.

y functioning

first or reverse gear, release the clutch pedal normally, you feel a non-judder occurs.

shock of the trimmings originates in an offsetting of the gear box or with

At the time of the gearbox accosting, it is recomme nded to maintain the engine and the gearbox aligned by using hoist o r jack until their

This shock causes instabilities of friction which are going to reveal a chatering at the time of the phase of

fixing. Take care to the conditions of the contact plan and the fixing

Control the alignment of the engine/gearbox and res pect the tightening

1. Chaterring : Jerky 1.5 Chattering - Grease centrifugation

Test Conditions : in 1st or reverse gear, the vehicle juddering during the release of clutch pedal,Defect Origin : t he linings are polluted by the presence of oil or grease.The pollution on the friction linings is irreversible, any attempt to clean the linings will not remove the defect.

VALEO adviceTo remove the source of pollution:

• check the condition of the engine and gearbox • check the correct conditions of the receiver or hydraulic bearing.

When reinstalling the new clutch, lubricate moderat ely with grease the bearing guide and the fork fingers.

y functioningcentrifugation

1st or reverse gear, the vehicle juddering during the release of clutch

linings are polluted by the presence of oil or grease.The pollution on the friction linings is irreversible, any attempt to clean the linings will not

the condition of the engine and gearbox spi seals.the correct conditions of the receiver or hydraulic bearing.

When reinstalling the new clutch, lubricate moderat ely with grease the

2. Noise : A noise is felt in neutral or in every speed passage 2.1 Noise - Presence of grease on the friction hub

Test Conditions : the engine is running, car stop and any speed is engage. The clutch pedal is not engaged. A sound of neutral point Defect Origin : the presence of grease on the hub, cant permits to filtrate the engine acyclisms. Friction won’t remove the defect.

VALEO adviceVALEO advice• Pollution of the friction by grease is irreversible, any atte mpt to clean will not remove the default.• When replacing the clutch it is recommended to use the s upplied grease without excess

A noise is felt in neutral or in every speed passage

Presence of grease on the friction hub

engine is running, car stop and any speed is engage. The clutch appears at the gearbox level.

presence of grease on the hub, cant permits to filtrate the engine

of the friction by grease is irreversible, any atte mpt to clean

replacing the clutch it is recommended to use the s upplied

2 Noise : A noise is felt in neutral or in every speed passage 2.2 Noise - Deterioration of the springs shock absorbers

Test Conditions : t he vehicle engine is running and in rolling phase, particularly on the first gear. A noise appears at the gearbox level.Defect Origin : t he noise is due to a clutch friction rupture of one or more springs shock absorbers, and damage the filtration characteristics of friction clutch.

Deterioration of the spring(s) is probably due to:1 - an excessive acyclism engine due to a deterioration of engine characteristic (bad engine management ,inhomogeneous cylinder compression, etc. ...)2 - a gearbox eccentricity, which will lead to wear or breakage of the bearing around the hub, this is due to damaged centering pin.

VALEO advice• Proceed to a motor gestion control.• When accosting the gearbox, using a jack to support the weight of the gearbox. As long as the screws used to fix the gearbox were not properly tightened and control the centering pins o f the gearbox.


Deterioration of the springs shock absorbers

vehicle engine is running and in rolling phase, particularly on the first gear.

noise is due to a clutch friction rupture of one or more springs shock absorbers, and damage the filtration characteristics of friction clutch.

excessive acyclism engine due to a deterioration of engine characteristic (bad engine management ,inhomogeneous cylinder compression, etc. ...)

gearbox eccentricity, which will lead to wear or breakage of the bearing around the hub, this is

control.using a jack to support the weight of

the gearbox. As long as the screws used to fix the gearbox were not properly tightened and control the centering pins o f the gearbox.

2. Noise : A noise is felt in neutral or in every speed passage 2.3 Noise and vibrations - Breakage of the guide slice and ejection of a spring

Test Conditions : the engine is running in driving conditions. A sound of neutral point appears at the gearbox level.Defect Origin : the beat of input shaft of limps, of the gearbox, constraints of the veil on the spring. The spring has used the washer guide until it breakage.

VALEO adviceAt the time of accosting , it is recommended to mai ntain the machine elements aligned using hoist or of jack until their fixing. Until the gearbox fixations are not correctly tightening.


Breakage of the guide slice and

engine is running in driving conditions. A sound of neutral

beat of input shaft of limps, of the gearbox, generated radial The spring has used the washer guide until it

At the time of accosting , it is recommended to mai ntain the machine elements aligned using hoist or of jack until their fixing. Until the gearbox fixations are not correctly tightening.

2. Noise : A noise is felt in neutral or in every speed passage 2.4 Noise- Springs clearance

The clearance of the filtration springs is not a defect.

This clearance permit to assimilate the jolts of the engine This clearance permit to assimilate the jolts of the engine gearbox (by association of the springs clearance When the engine is under operation, the springs will be fixed under the effect of the centrifugal force.


is not a defect.

This clearance permit to assimilate the jolts of the engine at neutral point of the This clearance permit to assimilate the jolts of the engine at neutral point of the the springs clearance degrees).

When the engine is under operation, the springs will be fixed under the effect of the

2. Noise : A noise is felt in neutral or in every speed passage 2.5 Slipping and noise - Blades breakage

Test Conditions : the vehicle engine running. impossibility of speed passing.Defect Origin : t he rupture of the blades on the progressive disc have for origin:

• a deformation of the friction at the time of accosting of gearbox. the friction supported whole or part of the weight of limps at speeds by the means of the input shaft.

• a strong offsetting of gearbox which makes work in inflection the disc.The deformation causes incipient fractures which are propagated until the total The deformation causes incipient fractures which are propagated until the total rupture of the feet of blade.

VALEO adviceVALEO adviceAt the time of an accosting of limps, it is recomme nded to maintain the machine elements aligned using hoist o r of jack until their fixing. A detailed attention must be gi ven to the state of the plans of contact. Ensured of driving alignme nt/gearbox and to respect the tightening torques of the screws of turn of limps.


Blades breakage

vehicle engine running. impossibility of speed passing.rupture of the blades on the progressive disc have for origin:

deformation of the friction at the time of accosting of gearbox. the friction supported whole or part of the weight of limps at speeds by the means of the input

strong offsetting of gearbox which makes work in inflection the disc.The deformation causes incipient fractures which are propagated until the total The deformation causes incipient fractures which are propagated until the total

At the time of an accosting of limps, it is recomme nded to maintain the machine elements aligned using hoist o r of jack until their fixing. A detailed attention must be gi ven to the state of the plans of contact. Ensured of driving alignme nt/gearbox and to respect the tightening torques of the screws of turn of

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.1 Slipping - Descent of the pedal, hydraulic systems

The sudden descent of the clutch pedal characteristic of a bad return of is butted • by dysfunction of the hydraulic system of the order.• by a leakage of the hydraulic circuit at transmitter level.

Dysfunction of hydraulic circuitThe transmitter and the receiver of clutch are oxidized, seized up, or blocked either by a permissive waste, or by the use of nonmiscible liquids of order.waste, or by the use of nonmiscible liquids of order.The liquid of order can be :

• old,• salted,• degraded,• not-in conformity with the specifications.

Hydraulic circuit leakageThe circuit is not tight any more, the volume of hydraulic liquid is not sufficient to move the abutment of mechanical or hydraulic clutch.

The inadequate position of the abutment entrains a fall of the load generated on the mechanism, pulling the slipping.

VALEO adviceTo carry out the repairing of the hydraulic control , to exchange all the defective components, to rinse and purge the circui t. To ensure itself of a return pedals frank, of a play of guard betwee n the stem of pushed and the transmitter, of the effectiveness within th e competence of preload integrated into the receiver..

The car doesn't accelerate in spite of it geared up the engine

Descent of the pedal, hydraulic systems

The sudden descent of the clutch pedal characteristic of a bad return of is butted dysfunction of the hydraulic system of the order.a leakage of the hydraulic circuit at transmitter level.

The transmitter and the receiver of clutch are oxidized, seized up, or blocked either by a permissive liquids of order.liquids of order.

The circuit is not tight any more, the volume of hydraulic liquid is not sufficient to move the abutment

The inadequate position of the abutment entrains a fall of the load generated on the mechanism, pulling the slipping.

To carry out the repairing of the hydraulic control , to exchange all the defective components, to rinse and purge the circui t. To ensure itself of a return pedals frank, of a play of guard betwee n the stem of pushed and the transmitter, of the effectiveness within th e competence of preload integrated into the receiver..

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.2 Slipping - Excess of grease on the bearing

Test Conditions : the engine is running, and in midspeeds). The car does not accelerate in spite of the mounted engine speed.Defect Origin : the excess of grease on the bearing spread in the center of friction to the linings. A linings pollution by grease, causes a brutal diminution of the friction coefficient.This diminution in the coefficient of friction causes the slippage.

VALEO adviceWhen reinstalling the new clutch sure to grease mod erately the

The pollution on the linings is irreversible, any attempt to clean the part will not remove the default

When reinstalling the new clutch sure to grease mod erately the bearing guide and the fork axe.


Excess of grease on the bearing

engine is running, and in mid-range acceleration (in particular on the latest speeds). The car does not accelerate in spite of the mounted engine speed.

excess of grease on the bearing spread in the center of friction to the linings. A linings pollution by grease, causes a brutal diminution of the friction coefficient.This diminution in the coefficient of friction causes the slippage.

When reinstalling the new clutch sure to grease mod erately the

is irreversible, any attempt to clean the part will not remove the default

When reinstalling the new clutch sure to grease mod erately the

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.3 Slipping - Bad return in position of the bearing

Test Conditions : the engine is running, the car does not accelerate despite mounted engine speedDefect Origin : the bad status of the clutch command can cause insufficient return of the bearing which causes a partial disengagement of the clutch mechanism.

This defect may come from a:• fraying of the metal core of the clutch cable (the cable locks into the sheath)• gumming or the fork axis.• gumming the ball joint.• parallelism defect of the fork fingers.• misalignment of the gearbox.

VALEO adviceWhen replacing the clutch it is imperative to contr ol and/or replace the clutch command .


Bad return in position of the bearing

engine is running, the car does not accelerate despite mounted engine speedbad status of the clutch command can cause insufficient return of the bearing

which causes a partial disengagement of the clutch mechanism.

of the metal core of the clutch cable (the cable locks into the sheath)

When replacing the clutch it is imperative to contr ol and/or replace the

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.4 Slipping - Destruction of the friction

Test Conditions : the engine is running, in driving phase, the car does not accelerate despite mounted engine speedDefect Origin : the destruction of the friction, pressure plate side, is consecutive to an high temperature of utilization , due to a prolonged slipping.

In this case, slipping is caused by:• bad return of the bearing due to the wear of the clutch command system, decreases the effort of pressure generated by the mechanism.

• the presence of the driver foot on clutch mechanism)

• severe conditions of utilization, presence of a overloaded trailer, travelling total weight.

VALEO advice•In case of important blueness or cracks on the flyw heel, it is recommended to replace it.•Check the condition of the bearing shaft fork, and replace if necessary.•The excessive heat in the clutch casing, may have d amaged the gearbox spy seal, it is recommended to replace it.


Destruction of the friction

engine is running, in driving phase, the car does not accelerate despite

destruction of the friction, pressure plate side, is consecutive to an abnormally high temperature of utilization , due to a prolonged slipping.

return of the bearing due to the wear of the clutch command system, which decreases the effort of pressure generated by the mechanism.

presence of the driver foot on clutch the pedal (generated an effort reduction on the

presence of a overloaded trailer, exceed the authorized

In case of important blueness or cracks on the flyw heel, it is

Check the condition of the bearing shaft fork, and replace if

The excessive heat in the clutch casing, may have d amaged the gearbox spy seal, it is recommended to replace it.

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.5 Slipping - Spy seal leak

Test Conditions : the engine is running, in driving phase, the car does not accelerate despite mounted engine speedDefect Origin : the slippage is due to pollution of the clutch linings by oil from the gearbox, this defect is probably caused by a leak of the gearbox side seal.

VALEO adviceAt the time of the clutch replacement, it is impera tive to check the status of the spy seals (engine and gearbox).


engine is running, in driving phase, the car does not accelerate despite

slippage is due to pollution of the clutch linings by oil from the gearbox, this gearbox side seal.

At the time of the clutch replacement, it is impera tive to check the (engine and gearbox).

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.6 Slipping - Linings pollution

Test Conditions : The engine is running, in driving phase, the car does not accelerate despite mounted engine speedDefect Origin:

•Gearbox or engine oil leakage.•An excessive lubrication of the primary drive shift splines or the bearing guide.•The slipping is probably the result of pollution by oil or grease of the lining, the friction lining is so degraded, the capacity of the clutch torque becomes insufficient.so degraded, the capacity of the clutch torque becomes insufficient.

VALEO adviceTo remove the sources of pollution, it is • control motor and gearbox spy seal• control motor and gearbox spy seal• control the receiver or hydraulic bearing• take care not to contaminate friction material with grea se during manipulation• moderately grease abutment guide and fork’s support


The engine is running, in driving phase, the car does not accelerate despite

An excessive lubrication of the primary drive shift splines or the bearing guide.The slipping is probably the result of pollution by oil or grease of the lining, the friction lining is so degraded, the capacity of the clutch torque becomes insufficient.so degraded, the capacity of the clutch torque becomes insufficient.

To remove the sources of pollution, it is recommended to:motor and gearbox spy sealmotor and gearbox spy sealthe receiver or hydraulic bearing

care not to contaminate friction material with grea se during

grease abutment guide and fork’s support

3. Slipping : The car doesn't accelerate in spite of it geared up the engine3.7 Slipping and noise - Blades breakage

Test Conditions : the vehicle engine running. impossibility of speed passing.Defect Origin : the rupture of the blades on the progressive disc have for

• deformation of the friction at the time of accosting of gearbox. the friction supported whole or part of the weight of limps at speeds by the means of the input shaft.

• strong offsetting of gearbox which makes work in inflection the disc.The deformation causes incipient fractures which are propagated until the total rupture of the feet of blade.rupture of the feet of blade.

VALEO adviceVALEO adviceAt the time of an accosting of limps, it is recomme nded to maintain the machine elements aligned using hoist or of jack unt il their fixing. A detailed attention must be given to the state of th e plans of contact. Ensured of driving alignment/gearbox and to respect the tightening torques of the screws of turn of limps.


Blades breakage

vehicle engine running. impossibility of speed passing.rupture of the blades on the progressive disc have for origin a:of the friction at the time of accosting of gearbox. the friction supported

whole or part of the weight of limps at speeds by the means of the input shaft.offsetting of gearbox which makes work in inflection the disc.

The deformation causes incipient fractures which are propagated until the total

At the time of an accosting of limps, it is recomme nded to maintain the machine elements aligned using hoist or of jack unt il their fixing. A detailed attention must be given to the state of th e plans of contact. Ensured of driving alignment/gearbox and to respect the tightening torques of the screws of turn of limps.

4. Bad speed changing :engage with difficulty in neutral or by driving 4.1 Bad speed passage and noise deteriorationTest Conditions : the vehicle engine is running. The phase.Defect Origin : a deformation of the cover (at the centering level).

Check the type of centering on the flywheel and the conformity of delivered cover(centering pins, diameter, flywheel recess and flat ...).

VALEO adviceEnsure that the mechanism is correctly positioned o n the flywheel centering pins, before tightening all.

4. Bad speed changing : Speeds engage with difficulty in neutral or by

4.1 Bad speed passage and noise - Cover deformation or

vehicle engine is running. The speed crack in driving or starting

deformation of the cover (at the centering level).

Check the type of centering on the flywheel and the conformity of delivered cover(centering pins, outer diameter, flywheel recess and flat ...).

Ensure that the mechanism is correctly positioned o n the flywheel centering pins, before tightening all.

4. Bad speed changing :engage with difficulty in neutral or by driving 4.2 Bad speed changing - Parallelism defect of the diaphragm fingers

The defect of parallelism of the fingers of the diaphragm is probably with a deformation of the mechanism to the right of a foot of centering

The lifting of the pressure plate is not uniform any more.

VALEO adviceDuring the replacement of a clutch, it is imperativ e to manipulate with

precaution the clutch. A fall of the mechanism is e nough or an unfortunate intervention during the assembly to dam age the mechanism.

4. Bad speed changing : Speeds engage with difficulty in neutral or by

Parallelism defect of the

The defect of parallelism of the fingers of the diaphragm is probably with a deformation of the mechanism to the right of a foot of centering

The lifting of the pressure plate is not uniform any more.

During the replacement of a clutch, it is imperativ e to manipulate with precaution the clutch. A fall of the mechanism is e nough or an unfortunate intervention during the assembly to dam age the

4. Bad speed changing :with difficulty in neutral or by driving 4.3 Bad speed changing - Deformation of leaf strips set

Test Conditions : the vehicle engine is running. The Defect Origin : a deformation of leaf strip set will entrain a bad release of the friction by deterioration of three sets of strips. An important shock on the mechanism can

The most sensitive gift are the first and the reverse (no synchronization).

VALEO adviceDuring the replacement of a clutch, it is imperativ e to manipulate with precaution the clutch. A fall of the mechanism is e nough or an unfortunate intervention during the assembly to dam age the leaf strip.The started of the engine by pushing or by pulling the vehicle, a bad change of report (ex: 5th / 2nd 90km / hour) also g enerates this type of degradation.


4. Bad speed changing : Speeds engage with difficulty in neutral or by driving

Deformation of leaf strips set

vehicle engine is running. The speed crack in driving or starting phase.deformation of leaf strip set will entrain a bad release of the friction by deterioration

An important shock on the mechanism can deteriorate a set leaf strips.


During the replacement of a clutch, it is imperativ e to manipulate with precaution the clutch. A fall of the mechanism is e nough or an unfortunate intervention during the assembly to dam age the leaf strip.The started of the engine by pushing or by pulling the vehicle, a bad change of report (ex: 5th / 2nd 90km / hour) also g enerates this type of


4. Bad speed changing :with difficulty in neutral or by driving 4.4 Bad speed changing – Flask sudden

Test Conditions : the vehicle engine running. impossibility of speed passing.Defect Origin :a flask perforation du to:

•A lack of pre load•A eccentricity of the gearbox•A buckling of the control rod.

The friction of the control rod to the flask (effect of flow) resulted in the unsetting stud and wear of the flask.

VALEO adviceBefore replacing the clutch with this type of command it is recommended to replace the control rod(in the gearbox).


Flask sudden wear (Volkswagen vehicle)

vehicle engine running. impossibility of speed passing.

The friction of the control rod to the flask (effect of flow) resulted in the unsetting of the contact

the clutch with this type of command it is control rod and the bearing roll support

4. Bad speed changing :with difficulty in neutral or by driving 4.5 Bad speed changing - Hard pedal

Test Conditions : the vehicle engine is running. The

Defect Origin: a defect of the command system.

If the system is with cable : it can act of a seizing of the fork in its stages and/or to the deterioration of the control cable because of an incorrect advance. These excessive constraints of the cable of clutch can involve its rupture.involve its rupture.

If the system is hydraulic: the transmitter and the receiver of clutch are oxidized, seized up, or blocked either by a permissive waste, or by the use of immiscible liquids of order. The bad return of the bearing decreases the effort of pressure generated by the mechanism what involves an slipping.

VALEO adviceAt the time of the replacement of the clutch it is recommended to change the fork, its axes, stages or the kneecap. T o check the state of the cable periodically its advance its fixings. It should not be in constraint or contact with bodies moving, arises an d zones of heat. Check if the purge of the hydraulic system and the correct operation of the transmitter and the receiver.


Hard pedal

vehicle engine is running. The speed crack in driving or starting phase.

it can act of a seizing of the fork in its stages and/or to the deterioration of the control cable because of an incorrect advance. These excessive constraints of the cable of clutch can

transmitter and the receiver of clutch are oxidized, seized up, or blocked either by a permissive waste, or by the use of immiscible liquids of order. The bad return of the bearing decreases the effort of pressure generated by the mechanism what involves an slipping.

At the time of the replacement of the clutch it is recommended to change the fork, its axes, stages or the kneecap. T o check the state of the cable periodically its advance its fixings. It should not be in constraint or contact with bodies moving, arises an d zones of heat. Check if the purge of the hydraulic system and the correct operation of

4. Bad speed changing :with difficulty in neutral or by driving 4.6 Bad speed changing - Routing and skewed of the bearing fork

Test Conditions : the vehicle engine is running. The Defect Origin: a command system in bad condition:An important traces of routing on the diaphragm indicates an abnormal wear, bearing preload.The skewed of the bearing and the rupture of the sleeve are du to the fork support outside of the bearing ears. The effect of diving of the fork is linked to substantial wear of it and the guide tube.

VALEO adviceAt the time of the replacement of the clutch it is imperative to check and replace if necessary the command system of the fingers) its fixing (stage, axis or kneecap) as well as the cable or hydraulic system and to take care of the good adjus tment of the pre load by requesting the fork contrary to the clutch of disengaging (20 to 40 Newton effort request).


Routing and skewed of the bearing fork

vehicle engine is running. The speed crack in driving or starting phase.in bad condition:

An important traces of routing on the diaphragm indicates an abnormal wear, caused by incorrect

The skewed of the bearing and the rupture of the sleeve are du to the fork support outside of the bearing ears. The effect of diving of the fork is linked to substantial wear of it and the guide tube.

At the time of the replacement of the clutch it is imperative to check and replace if necessary the command system as the fork (alignment of the fingers) its fixing (stage, axis or kneecap) as well as the cable or hydraulic system and to take care of the good adjus tment of the pre load by requesting the fork contrary to the clutch of disengaging (20 to

4. Bad speed changing :with difficulty in neutral or by driving 4.7 Bad speed passage - Deterioration of the hub grooves

Test Conditions : the vehicle engine running. The Defect Origin : the landing force of the shaft of the box spline hub is causing the deterioration of the splines (presence of large burrs and ). The friction slides on bad input shaft which disrupts the phases of réclutching. During the walkout by licking it remains with the flywheel which rotates. The shifting is difficult.

VALEO adviceAt the time of accosting, it is recommended to supp ort limps it speeds by a hoist and slightly to lubricate the input shaf t in order to facilitate the assembly and the sliding motion of the friction .


Deterioration of the hub grooves

speed crack in driving or starting phase.landing force of the shaft of the box spline hub is causing the deterioration of the

splines (presence of large burrs and ). The friction slides on bad input shaft which disrupts the phases of the walkout by licking it remains with the flywheel which rotates. The shifting is

At the time of accosting, it is recommended to supp ort limps it speeds by a hoist and slightly to lubricate the input shaf t in order to facilitate the assembly and the sliding motion of the friction .

4. Bad speed changing :with difficulty in neutral or by driving 4.8 Bad speed passage - rocking of the diaphragm

Test Conditions : the vehicle engine running. The Defect Origin : the over-travel of the bearing at the stage of disengagement is the source of an excessive tilting of the diaphragm.Traces of circular interference in the internal part of the diaphragm showed that overFriction is pressed against the flywheel.This flaw exists ONLY on a push diaphragm mechanism

Control to be done: ré clutch. How to check those points?

•Point of declutching: gently as possible on the pedal towards the floor, when speed can be pledged (ratio 1 or reverse) is that the point is reached and release be at about 2/3 of the pedal stroke, taking into account the reference point is in the upper position the pedal

•Point of re clutching: pedal to the floor, shift into gear, the clutch pedal up as gently as possible, when the vehicle starts to move (any wheel rotation), reengagement point must be located slightly above the declutching clutch.

VALEO adviceAt the time of the replacement of the clutch it is imperative to check the adjustment of the order (height pedals, play takeThe points of clutch and D clutch must be to the 2/ 3 of the race pedals.

above the declutching clutch. Between the point of de clutching and re clutching, we must have had around 10 mm gap between both. In case you have much more than 10 mm apart, this indicates a command in a very bad state, and it must change imperative

Bad speed changing : Speeds engage with difficulty in neutral or by driving

rocking of the diaphragm

speed crack in driving or starting phase.travel of the bearing at the stage of disengagement is the source of an

Traces of circular interference in the internal part of the diaphragm showed that over-travel.

on a push diaphragm mechanism and coupled to an adjustable cable control.

Control to be done: the points of declutching and of clutch. How to check those points?

Point of declutching: high pedal position, press gently as possible on the pedal towards the floor, when speed can be pledged (ratio 1 or reverse) is that the point is reached and release be at about 2/3 of the pedal stroke, taking into account the reference point is in the upper position the pedal

pedal to the floor, shift into gear, the clutch pedal up as gently as possible, when the vehicle starts to move (any wheel rotation), reengagement point must be located slightly

At the time of the replacement of the clutch it is imperative to check the adjustment of the order (height pedals, play take -up etc,)The points of clutch and D clutch must be to the 2/ 3 of the race pedals.

Between the point of de clutching and re clutching, we must have had around 10 mm gap between

In case you have much more than 10 mm apart, this indicates a command in a very bad state, and

5. Impossibility of speed changing :do not engage.5.1 Impossibility of speed passing -car)

Test Conditions : the vehicle engine running. impossibility of speed passing.Defect Origin : a flask perforation can be due du to:

•A lack of pre load•A eccentricity of the gearbox•A buckling of the control rod.•A buckling of the control rod.

VALEO adviceBefore replacing the clutch with this type of command it is recommended to replace the control rod(in the gearbox).

The friction of the control rod to the flask (effect of flow) resulted in the unsetting perforation of the flask.

Impossibility of speed changing : Speeds

- Perforated flask ( Volkswagen

vehicle engine running. impossibility of speed passing.flask perforation can be due du to:

the clutch with this type of command it is control rod and the bearing roll support

The friction of the control rod to the flask (effect of flow) resulted in the unsetting of the contact stud and

5. Impossibility of speed changing :do not engage.5.2 Difficulty / Impossibility of speed changing hub grooves

Test Conditions : the vehicle engine running, impossibility of speed passing.Defect Origin : the accosting in force of the input shaft of limps in the multiple spline hub is at the origin of the deterioration of the grooves (important presence of burs and matter repression).The friction cannot slide on the input shaft what disturbs the phases of rechattering. At the time of disengaging it remains in contact with the driving wheel which rotates it. The chattering. At the time of disengaging it remains in contact with the driving wheel which rotates it. The passage speeds is impossible

VALEO adviceAt the time of accosting, it is recommended to supp ort limps it speeds by a hoist and slightly to lubricate the input shaf t in order to facilitate the assembly and the sliding motion of the friction .


Difficulty / Impossibility of speed changing - Deterioration of the

vehicle engine running, impossibility of speed passing.accosting in force of the input shaft of limps in the multiple spline hub is at the origin

of the deterioration of the grooves (important presence of burs and matter repression).The friction cannot slide on the input shaft what disturbs the phases of re-engagement and generates chattering. At the time of disengaging it remains in contact with the driving wheel which rotates it. The chattering. At the time of disengaging it remains in contact with the driving wheel which rotates it. The

At the time of accosting, it is recommended to supp ort limps it speeds by a hoist and slightly to lubricate the input shaf t in order to facilitate the assembly and the sliding motion of the friction .

5. Impossibility of speed changing :do not engage.5.3 Impossibility of speed changing

Test Conditions : the vehicle engine is running. The Defect Origin : a bad clipping of the bearing may be probably due

• misalignment between the gearbox and engine.• misalignment of the fork fingers creates a nonoperation of clispage. (See photo)

VALEO adviceTo ensure an adequate clipping of the bearing do the followin g steps:

1. Fit the clutch on the flywheel (mechanism + disk), and ensure that all is properly centered, in particular the friction.

2. Place the bearing on the guide and on the fork.2. Place the bearing on the guide and on the fork.3. Coupling the gearbox.4. Tighten the gearbox on the engine.5. Clip the bearing by creating a force on the fork op posite to the clutch

engagement.6. Check the good clipping by actionning the fork in t he direction of clutch

disengagement.

To check if the clip is correct proceed as follows:Start the engine, set foot on the clutch pedal catc hing clearance 10pedal. If the driver's foot feels a vibration comin g from the pedal, the partial clip is proved.


Impossibility of speed changing - Unsetting of the bearing sleeve

vehicle engine is running. The speed crack in driving or starting phase.bad clipping of the bearing may be probably due to a:

between the gearbox and engine.of the fork fingers creates a non-uniform support on the bearing during the

an adequate clipping of the bearing do the followin g steps:Fit the clutch on the flywheel (mechanism + disk), and ensure that all is properly centered, in particular the friction.Place the bearing on the guide and on the fork.Place the bearing on the guide and on the fork.

Clip the bearing by creating a force on the fork op posite to the clutch

Check the good clipping by actionning the fork in t he direction of clutch

To check if the clip is correct proceed as follows:Start the engine, set foot on the clutch pedal catc hing clearance 10 -15 mm at the pedal. If the driver's foot feels a vibration comin g from the pedal, the partial clip is


Test Conditions : the vehicle engine running, impossibility of speed passing.Defect Origin : t The destruction of the grooves have probably for origin an abnormally high driving acyclism which generate the shocks of the input shaft on the grooves of the hub.generated efforts until the shearing of the grooves.

VALEO adviceIn this case it is recommended to proceed a development of the engine (ignition, carburetion, i njection).


Impossibility of speed changing - Destruction of the hub grooves

vehicle engine running, impossibility of speed passing.destruction of the grooves have probably for origin an abnormally high driving

acyclism which generate the shocks of the input shaft on the grooves of the hub. These shocks

In this case it is recommended to proceed a functional check and the development of the engine (ignition, carburetion, i njection).

5. Impossibility of speed changing :do not engage.5.5 Impossibility of speed changing spring ejection

In this case, the impossibility of passing speeds is consecutive with the destruction of the hub friction shock absorber.

A strong driving acyclism is probably at the origin of the ejection of the spring shock absorber and the deterioration of the others.

The springs are calculated to absorb the acyclisms engine (with blows, very fast variation angular velocity transmitted to the mechanism by the driving wheel) in a definite beach. If the engine presents one dysfunction, the springs will box abnormally high efforts, will worsen, deform

VALEO adviceIn this case it is recommended to carry out the fun ctional check driving and if necessary to reprogram the cartography engin e in order to avoid a repetition. An inappropriate control (strong requ est; with blows; jerks) also causes this type of deterioration.

engine presents one dysfunction, the springs will box abnormally high efforts, will worsen, deform then to break the window of the veil and disc of guidance. The noted defect cannot be ascribable in Valeo.


Impossibility of speed changing - Destruction of the hub and

In this case, the impossibility of passing speeds is consecutive with the destruction of the hub friction

A strong driving acyclism is probably at the origin of the ejection of the spring shock absorber and the

The springs are calculated to absorb the acyclisms engine (with blows, very fast variation angular velocity transmitted to the mechanism by the driving wheel) in a definite beach. If the engine presents one dysfunction, the springs will box abnormally high efforts, will worsen, deform

In this case it is recommended to carry out the fun ctional check driving and if necessary to reprogram the cartography engin e in order to avoid a repetition. An inappropriate control (strong requ est; with blows; jerks) also causes this type of deterioration.

engine presents one dysfunction, the springs will box abnormally high efforts, will worsen, deform then to break the window of the veil and disc of guidance. The noted defect cannot be ascribable


Test Conditions : the vehicle engine running. The Defect Origin : the over-travel of the bearing at the stage of disengagement is the source of an excessive tilting of the diaphragm.Traces of circular interference in the internal part of the diaphragm showed that overFriction is pressed against the flywheel.This flaw exists ONLY on a push diaphragm mechanism

VALEO adviceAt the time of the replacement of the clutch it is imperative to check the adjustment of the order (height pedals, play takeThe points of clutch and D clutch must be to the 2/ 3 of the race pedals.


Impossibility of speed changing - rocking of the diaphragm

speed crack in driving or starting phase.travel of the bearing at the stage of disengagement is the source of an

Traces of circular interference in the internal part of the diaphragm showed that over-travel.

on a push diaphragm mechanism and coupled to an adjustable cable control.

At the time of the replacement of the clutch it is imperative to check the adjustment of the order (height pedals, play take -up etc,)The points of clutch and D clutch must be to the 2/ 3 of the race pedals.

5. Impossibility of speed changing :do not engage 5.7 Impossibility of speed changing

Test Conditions : the vehicle engine running. impossibility to speed passing.Defect Origin : the impossibility of disengaging is consecutive to the breakage of the pressure plate.This breakage is caused by an abnormally high operating temperature, which had with a prolonged slipping (the two trimmings are burned).The rise and the variation in temperature enter the face of friction (700the ambient air of the casing (100°with 150° ), constrained the plate to be become deformed beyond its mechanical resistance (rupture).mechanical resistance (rupture).

In this case, slipping is caused either by:• bad return of the bearing due to the wear of the elements .• a blocking of the automatic wear cable.• presence of the foot of the driver on the pedal)

This cases reduce the effort generated by the mechanism on the linings


Impossibility of speed changing - Breakage of the pressure plate

vehicle engine running. impossibility to speed passing.impossibility of disengaging is consecutive to the breakage of the pressure plate.

This breakage is caused by an abnormally high operating temperature, which had with a prolonged

The rise and the variation in temperature enter the face of friction (700°) and the back face in contact with ), constrained the plate to be become deformed beyond its

return of the bearing due to the wear of the elements .

of the foot of the driver on the pedal)This cases reduce the effort generated by the mechanism on the linings

5. Impossibility of speed changing :do not engage 5.8 Impossibility of speed changing of pre-load)

Test Conditions : the vehicle engine running. impossibility to speed passing.Defect Origin : the deterioration of the bearing consecutive with a lack of pre load which generated a heating by slip of the bearing on the diaphragm (heating by difference in number of revolutions).the effect of heat the bearing seized up. The bearing was encrusted in the fingers with the diaphragm (advance) until total cutting with the fingers with the diaphragm.rub on the diaphragm. The strong rise in temperature dissolved the polyamide sleeve and the seal of the rub on the diaphragm. The strong rise in temperature dissolved the polyamide sleeve and the seal of the bearing.

VALEO adviceAt the time of the replacement of the clutch it is imperative to check and give in state the control units, in particular the fork and its articulation (stage, axis or kneecap) and to check the preload (generally 50 to 100 Newton).


Impossibility of speed changing - Destruction of the bearing (lack

vehicle engine running. impossibility to speed passing.deterioration of the bearing consecutive with a lack of pre load which generated a

heating by slip of the bearing on the diaphragm (heating by difference in number of revolutions). Under the effect of heat the bearing seized up. The bearing was encrusted in the fingers with the diaphragm (advance) until total cutting with the fingers with the diaphragm. The fixed cage of the bearing came to rub on the diaphragm. The strong rise in temperature dissolved the polyamide sleeve and the seal of the rub on the diaphragm. The strong rise in temperature dissolved the polyamide sleeve and the seal of the

At the time of the replacement of the clutch it is imperative to check and give in state the control units, in particular the fork and its articulation (stage, axis or kneecap) and to check the preload (generally


Test Conditions : the vehicle engine running. impossibility to speed passing.Defect Origin : the over-stroke of the abutment has caused a shift too much of the diaphragm, extending beyond the strength of the diaphragm.

VALEO adviceIt is important to check the correct movement of th e release bearing and its stroke. To do this make sure the condition of the control system and its stroke. To do this make sure the condition of the control system (state of the cable, fork, ball, transmitter and re ceiver, pedal height).This defect appears on a low mileage product.


Impossibility of speed changing - diaphragm broken

vehicle engine running. impossibility to speed passing.stroke of the abutment has caused a shift too much of the diaphragm, extending

It is important to check the correct movement of th e release bearing and its stroke. To do this make sure the condition of the control system and its stroke. To do this make sure the condition of the control system (state of the cable, fork, ball, transmitter and re ceiver, pedal height).This defect appears on a low mileage product.

5. Impossibility of speed changing :do not engage 5.10 Impossibility of speed changing throat (lack of pre-load)

Test Conditions : the vehicle engine running. impossibility to speed passing.Defect Origin : lack of pre-loadThe lack of pre load is at the origin of inclined wear of the positioning throat friction with the snap ring.The throat cannot retain any more the snap ring which opens while slipping on the slope what involves the unhooking of the bearing.

VALEO adviceAt the time of the replacement of the clutch it is imperative to check and give in state the control units, in particular the fork and its articulation (stage, axis or kneecap, preload sprin g) .


Impossibility of speed changing - Wear of the of the positioning

vehicle engine running. impossibility to speed passing.

The lack of pre load is at the origin of inclined wear of the positioning throat friction with the snap ring.The throat cannot retain any more the snap ring which opens while slipping on the slope what involves

At the time of the replacement of the clutch it is imperative to check and give in state the control units, in particular the fork and its articulation (stage, axis or kneecap, preload sprin g) .


Test Conditions : the vehicle engine running. impossibility to speed passing.Defect Origin : any D-clutch is possible at the mecnismtransmitted by the wheels what results in to make work the strips in compression what generates the destruction of the strips.This defect is probably du to :

• a bad change of report/ratio (ex: 5th/2nd with 90km/h).• the startup of the engine while pushing or by drawing the vehicle


Impossibility of speed changing - Set of strips torn

vehicle engine running. impossibility to speed passing.mecnism level, du to a torn of the strips.The couple is

transmitted by the wheels what results in to make work the strips in compression what generates the

bad change of report/ratio (ex: 5th/2nd with 90km/h).startup of the engine while pushing or by drawing the vehicle


Test Conditions : the vehicle engine is running. The Defect Origin : the difficult passage speeds is consecutive with a bad release of the friction by deterioration of three sets of strips. An important shock on the strips.

VALEO adviceDuring the replacement of a clutch, it is imperativ e to manipulate with precaution the clutch. A fall of the mechanism is e nough or an unfortunate intervention during the assembly to dam age the leaf strip.The started of the engine by pushing or by pulling the vehicle, a bad change of report (ex: 5th / 2nd 90km / hour) also g enerates this type of degradation.



Impossibility of speed changing - Deformation of leaf strips set

vehicle engine is running. The speed crack in driving or starting phase.difficult passage speeds is consecutive with a bad release of the friction by

important shock on the mechanism can deteriorate a set leaf

During the replacement of a clutch, it is imperativ e to manipulate with precaution the clutch. A fall of the mechanism is e nough or an unfortunate intervention during the assembly to dam age the leaf strip.The started of the engine by pushing or by pulling the vehicle, a bad change of report (ex: 5th / 2nd 90km / hour) also g enerates this type of


6. Lexicon / Définition6.1 Clutch environment

6.2 Clutch components

6. Lexicon / Définition6.3 Definition of motor acyclisms

The perceived noise originates from a bad filtration of the vibration and

•The rotation of the crankshaft + flywheel + clutch is subjected to cyclic irregularities.•This acyclism is the sum of effect due to a couple of gas (explosion) and to the torque of inertia forces (connecting rods)

•Their importance varies, first, according to engine rpm, on the other hand, depending on the load of the car.

•For a given motor, the acyclisms depends linearly on the inertia of the rotating •For a given motor, the acyclisms depends linearly on the inertia of the rotating assembly (crank + flywheel + clutch)

www.valeoservice.comValeo Service Export70, rue Pleyel - 93285 Saint-Denis Cedex - FranceTél. : +33 (0)1 49 45 32 32 - Fax : +33 (0)1 49 45 36 59

/ DéfinitionDefinition of motor acyclisms

The perceived noise originates from a bad filtration of the vibration and acyclisms.

rotation of the crankshaft + flywheel + clutch is subjected to cyclic irregularities.This acyclism is the sum of effect due to a couple of gas (explosion) and to the torque of inertia forces (connecting rods)Their importance varies, first, according to engine rpm, on the other hand,

For a given motor, the acyclisms depends linearly on the inertia of the rotating For a given motor, the acyclisms depends linearly on the inertia of the rotating

Valeo S

ervice -S

ociété par Actions S

implifiée -

Capital 12 900 000 €

-306 486 48 R

.C.S

. Bobigny

306 486 48 R.C

.S. B

obigny -70, rue P

leyel 93200 Saint-D

enis France

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