OVERHAULING OF SINGLE PLATE CLUTCH

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AIM:
 
   OVERHAULING OF SINGLE PLATE CLUTCH

TOOLS REQUIRED

1. DOUBLE END OPEN SPANNER SET
2. DOUBLE END RING SPANNER SET
3. TRY SQUARE
4. SPRING COMPRESSOR
5. SCREW DRIVER (-)
6. CLUTCH JIG

MATERIALS REQUIRED

1. KEROSENE OIL
2. COTTON WASTE
3. EMERY PAPER

PROCEDURE

Task 1:

DISMANTLE THE CLUTCH

1. Mark with some paint the position of the clutch cover and flywheel.

2. While resetting, this mark will be aligned to ensure the original position of the clutch cover and the flywheel so that the balancing of the flywheel and clutch cover does not get disturbed.

3. Remove the locking wire of the clutch cover mounting set screws.

4. Unscrew the diagonally opposite mounting set screws  of the clutch cover. Each screw should be loosened by two turns at a time, If these screws are loosened and removed all at once, then the spring pressure will act on the remaining screws and the screw thread in the flywheel may shear.

5. Remove the clutch cover assembly and the clutch plate  from the flywheel.

Task 2:

CLEAN THE CLUTCH

1. Clean the parts of the clutch with kerosene and then dry and clean with a cloth.

Task 3:

CHECK FOR DEFECTS IN CLUTCH

1. Check the free rotation of the inner race of the bearing by hand. Replace the pilot bearing if found damaged.

2. Check the clutch plate for its free movement on the spline of the drive shaft by moving the clutch plate on the drive shaft's spline.


Task 4:

RECTIFY AND REFIT THE CLUTCH

Assembling

1. Clean the pegs of the flywheel and pressure plate.

2. Place the clutch plate on the flywheel keeping the clutch plate's hub opposite to the flywheel.

3. Use the aligning arbor to centralize the clutch plate. The arbor's end should sit in the pilot bearing.

4. Place the clutch cover assembly on the flywheel and align the mark of the flywheel and the clutch cover assembly

5. Tighten the mounting set screws of the clutch cover assembly evenly and diagonally arbor does not shift from the pilot bearing while tightening the mounting screws of the clutch cover.

6. Otherwise the clutch plate will not remain in the centre position and the gearbox drive shaft will not enter the pilot bearing

7. Remove the aligning arbor.

8. Lock the mounting screws of the clutch cover by wire.

9. Figure shows a sectional view of a single plate dry clutch for a light vehicle.

Replacing coil spring type clutch on a four wheeler

Task 5:

 OVERHAULING CLUTCH ASSEMBLY

DISMANTLING

1) Mark the pressure plate's and clutch cover's position with respect to each other.

2) Place the clutch assembly on the clutch jig aligning the slots on the clutch jig with the thrust pad's seat on the pressure plate

3. Compress the spring cups by the clutch jig

4. Loosen the pressure pad's mounting screw and remove the pressure pads.

5. Release the load from the spring cups.

6. Remove the pressure plate, springs, clutch cover assembly and the pressure pads from the clutch jig.

7. Loosen the mounting set screws of the retaining plate and remove the retaining plate.

8. Loosen the mounting set screws of the clutch finger bracket and remove the clutch fingers, brackets and eccentric pin.

INSPECTION

1. Visually check the flywheel, ring gear and pressure plate for cracks and burnt spots.

2. Check the flatness of the friction faces of the pressure plate and flywheel with a straight edge.

3. If flatness is not found within the specified limit then the pressure plate and flywheel can be ground. Do not grind below the minimum specified thickness.

Check the flowing parts for any damage/crack visually.

  🛑 Clutch fingers

  🛑 Clutch finger brackets

  🛑 Thrust pad

  🛑 Eccentric pin and bush

  🛑 Withdrawal plate

  🛑 Withdrawal bearing

  🛑 Clutch linkages


Check the free length and tension of the pressure springs Replace springs which do not conform to the manufacturer's specification.

Check the clutch plate's torsion spring visually for any damage. Replace the clutch plate if the torsion spring found damaged.

Measure the thickness of the clutch liner. Reline if the thickness of the liner is less than the minimum specified.

ASSEMBLING

1. Place the clutch finger's bush in the clutch finger. .

2. Fit the clutch finger bracket on the clutch cover and fit the clutch finger with the bracket with the eccentric pin.

3. Hand tighten the mounting set screws of the clutch bracket.

4. Place the pressure plate on the clutch jig.

5. Place the pressure springs on the spring recess of the pressure plate.

6. Align marks of the clutch cover and pressure plate and place the clutch cover on the pressure plate.

7. Compress the springs with a clutch jig.

8. Place the pressure pad on the pressure plate and tighten the pad's mounting set screws,

9. Release the load from the springs and remove the clutch cover assembly from the clutch jig.

10. Place the withdrawal plate on the clutch finger.

11. Place the withdrawal plate's retaining plate on the clutch fingers and tighten the mounting set screws of the withdrawal plate.

RESULT:

Overhauling of single plate clutch is done successfully.

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