Description And Operation: Description
Never use any type of petroleum-based fluid (engine oil, transmission oil, power steering fluid, etc.) in the clutch hydraulic system. Use of such fluids will result in master/slave cylinder seal damage, and cause a failure of the hydraulic clutch release system.
Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it off immediately with water.
Do not contaminate the friction material with grease or oil since this may cause excessive slippage between the pressure plate and the clutch discs burning the friction material leading to an early failure of the clutch.
CLUTCH
The clutch assembly controls the transfer of torque from the engine flywheel to the manual transmission input shaft. The clutch assembly consists of three parts, the two discs and cover. The clutch disc consists of multiple friction material surfaces positioned on a metal frame and a free floating center hub. The clutch discs may have damping characteristics. The clutch cover assembly consists of a cast pressure plate and heat treated steel spring contained under a stamped steel cover. It is bolted to the engine flywheel and exerts load against the clutch friction disc. The spring is segmented at the inside diameter. These segments (called fingers) are compressed by the clutch release bearing.
FLYWHEEL
The Dual Mass Flywheel is used on all engines. The flywheel incorporates the ring gear (5) around the outer circumference to mesh with the starter to permit engine cranking. The primary flywheel (6) side is bolted to the crankshaft. The secondary flywheel (3) side serves as the driving member to the clutch disc. Internal springs (4) between the flywheels are use to dampen energy. The Dual Mass Flywheel is serviced as an assembly only and should never be taken apart.
The flywheel is bolted firmly to the crankshaft which transmits part of the engine torque to the clutch disc. The rest of the torque passes into the cover through the bolts holding the clutch to the flywheel. From there, the straps transfer it to the clutch pressure plate. The diaphragm spring clamps the pressure plate against the clutch disc to achieve positive lock-up with flywheel. The clutch disc transmits the entire engine torque to the transmission via splined connection to the transmission input shaft. When the driver depresses the clutch pedal, the release bearing actuate the diaphragm spring pivots on this fulcrum ring, so that the outside diameter moves away from the pressure plate. This causes the preloaded drive straps to pull the pressure plate away from the clutch disc, interrupting torque transmission. When the driver release pedal, the outer portion of the diaphragm springs acts on the pressure plate which clamps the clutch disc between the pressure plate and the flywheel.
CLUTCH HYDRAULIC SYSTEM
The hydraulic clutch system uses brake fluid stored in the brake master cylinder reservoir (1). The clutch supply hose (2) picks up the fluid at a point above the minimum brake fluid level and provides fluid to the clutch master cylinder (4). This allows the brake system to maintain an adequate volume of fluid to operate in the event of a fluid leak in the hydraulic clutch system.
The clutch master cylinder is located inside the passenger compartment and mounted to the pedal sled. The clutch pedal (3) is directly connected to the clutch master cylinder (4). The Concentric Slave Cylinder (CSC) (6) is mounted in the bellhousing and has an integrated clutch release bearing, it is connected to the clutch master cylinder by a multi-piece fluid line (5).