Clutch and Cooling system

ALLEN JOHN VARGAS

MARY JUNE FELONGCO
JAILEEN LIZA

Clutch System
Introduction

The first stage in the transmission of a car with a manual

gearbox is the clutch.
Most cars use a friction clutch operated either by fluid
(hydraulic) or, more commonly, by a cable.
When a car is moving under power, the clutch is
engaged. A pressure plate bolted to the flywheel exerts
constant force, by means of a diaphragm spring, on the
driven plate.
Earlier cars have a series of coil springs at the back of
the pressure plate, instead of a diaphragm spring.

Key components:
Cover: a steel stamping or casting that houses the clutch components
and attaches to the flywheel.
Pressure plate: a cast iron plate that provides a pivot fulcrum for the
diaphragm spring, a friction surface for the disc and a mounting surface
for the drive straps.
Diaphragm spring: a flat, spring-steel disc compressed between the
cover and pressure plate that, when pushed by the release bearing,
engages and disengages the clutch.
Clutch flywheel: is connected directly to the engine crankshaft and,
therefore, spins with the engines motions.
Drive straps: flat, spring-steel strips that attach the pressure plate to
the clutch cover and help lift the pressure plate away from the disc to
disengage the clutch.
Clutch flywheel, is connected directly to the engine crankshaft and,
therefore, spins with the engines motions.
Clutch disc, has friction surfaces similar to a brake pad on both sides
that make or break contact with the metal flywheel and pressure plate
surfaces, allowing for smooth engagement and disengagement.

Clutch Faults, Causes, Remedies

PROBLEM

JUDDER
(to vibrate rapidly
and with force)

SYMPTOMS

CAUSES

REMEDIES

When the clutch

is re-engaged by
the gradual
release of the
clutch pedal but,
instead of a
smooth take-up,
the combined
engine-andgearbox unit
shudders and
vibrates.

(a) Worn-out
engine and
gearbox rubber
mountings.

a)Replace the
mountings.

(b) Engine
movement during
the take-up of the
drive, often
caused due to
body-to-engine
tie-bar out of
alignment.

(c) The pressureplate may be out

of parallel with
the flywheel face.

b)Rectify the drive

line or suspension
points.

c)Reposition the
pressure-plate, en
suring fitting of
the location
dowels and
evenly tightening
of the set-bolts.

PROBLEM

SLIP

Drag or
Spin

SYMPTOMS

CAUSES

REMEDIES

When a gear ratio

has been selected,
the clutch pedal
has been released
and the accelerator
pedal has been
pushed down, and
yet no power is
transmitted to the
driving wheels
although the
engine accelerates.
Also there may be
smell of burning
asbestos.
When it is difficult
to engage a gear
either when the
vehicle is
stationary or in
motion, due to the
driven-plate being
dragged around
even after the
clutch pedal has
acted to release it.
In worst case,
vehicle continues
to move even when

Glazing of the
surfaces, caused
by oil or grease on
the friction faces
due to leakage
from the engine
crankcase or the
gearbox or to
excessive
lubrication .
Clutch
mechanism binding
and incorrectly
adjusted clutch
pedal i.e. no free
Oil
ormovement
grease on or
pedal
the
driven-plate
partial
seizure of
faces.
linkage

Clean the
components and
renew the drivenplate.

Misalignment
between the
engine and the
splined clutchshaft.

Check the linkage,

rectify interference
and adjust the
linkage to provide
correct clearance.
Clean the
components,
lubricate the
splined shaft and
spigot bearing, and
renew the driven
plate.
(b)Check the
alignment of the
engine-to-gearbox
housing joint and
realign.

Difference between automatic

and
clutch
The manual
primary difference
between an automatic and a manual

transmission is the method the car uses to shift gears. In an

automatic transmission, the car decides when you shift and
automatically changes gears for you. In a manual transmission
car, you are responsible for shifting gears using the clutch and
gas pedals.

There are three main differences between manual and

automatic transmission vehicles: A manual transmission
vehicle has a gear shift which allows you to physically shift the
transmission into the proper gear. It also includes a clutch
pedal which unlocks the gears so you can safely shift it into
the next gear.
Automatics also have a clutch except instead of a clutch pedal
a torque converter. By having a torque converter, which
permanently connects the engine and the transmission,
automatics avoid having to disengage and re-engage a clutch
whenever gears are changed or the car comes to a stop.

Difference between automatic

and manual clutch

Costs
Manual transmissions cost less than automatics to begin with. When you go
to a car dealear you will notice that the stick-shift version of the same model
is about a thousand bucks cheaper.
In the long run, manuals require less service, thus making maintenance
cheaper too.
Maintenance
Any mechanic can tell you that working on a manual transmission is much
easier than working with automatic gear boxes. So the repair costs for
automatics are significantly higher.
Manuals - if properly operated - will go hundreds of thousands of kilometers
without problems (well, you also need a good car). The lubricant needs to
be replaced periodically but not as frequently as in automatics. (Some cars
use special transmission fluids that do not need to be replaced at all.)

Repair and Maintenance

If the flywheel is worn, have a professional resurface it.

This procedure involves grinding it down to a new, flat surface and then
polishing it to a mirror-like finish. If you fail to have this work done, the worn
flywheel can wear out the facing of the new clutch disk very quickly. And if
youve already had the disk replaced, chances are that it managed to score
the flywheel by the time you recognized the trouble signs and had the disk
attended to.

If the pressure plate is excessively worn, scored, or glazed; or if the

springs on the pressure plate become loose, you should have them
replaced, as well.

Because excessive wear on any part of your clutch results in wear on the
other parts, its generally a good idea to have the clutch assembly, levers,
clutch disk, and throwout bearings checked and, if necessary, replaced at
the same time.

Clutch Care
Driver error or abuse of the clutch can void your warranty.
Driver error/abuse includes:

Revving the engine excessively when starting out.

Resting your foot on the clutch pedal.
"Riding" the clutch (same as resting, but with more pressure)
Pulling heavy load
Rocking the vehicle from 1st & reverse when stuck in mud or snow.
Drivers inexperienced in driving stick shift transmissions.
Slipping the clutch excessively for any reason.
Lugging the engine/clutch by being in too high of a gear for the
vehicle speed.

Cooling System

Actually, there are two types of cooling systems found on motor

vehicles: Liquid cooled and Air cooled. Air cooled engines are
found on a few older cars. Many modern motorcycles still use air
cooling, but for the most part, automobiles and trucks use liquid
cooled systems and that is what this article will concentrate on.

A water-cooled engine block and cylinder head have interconnected

coolant channels running through them. At the top of the cylinder
head all the channels converge to a single outlet.
A pump, driven by a pulley and belt from the crankshaft, drives hot
coolant out of the engine to the radiator, which is a form of heat
exchanger.

Components of a Cooling Systems:

Radiator, the core is usually made of flattened aluminum tubes with aluminum strips that zigzag
between the tubes. These fins transfer the heat in the tubes into the air stream to be carried
away from the vehicle.
Water pump is a simple device that will keep the coolant moving as long as the engine is
running. It is usually mounted on the front of the engine and turns whenever the engine is
running.

Thermostat is simply a valve that measures the temperature of the coolant and, if it is hot
enough, opens to allow the coolant to flow through the radiator.

Radiator pressure cap is a simple device that will maintain pressure in the cooling system up to
a certain point. If the pressure builds up higher than the set pressure point, there is a spring
loaded valve, calibrated to the correct psi, to release the pressure.

Radiator Fans, mounted on the back of the radiator on the side closest to the engine is one or
two electric fans. These fans are there to keep the air flow going through the radiator while the
vehicle is going slow or is stopped with the engine running.

Coolant reservoir is a container that holds the excess or overflowing coolant, fluid or cooling
agent which is used in the cooling system. It is usually a clear plastic bottle located near the
radiator.

Indicatations that my engines coolant needs

exchanging or inspection

Low coolant levels: If your coolant is low, you could have a leak in
your cooling system. You may be able to see the leak under your
vehicle, and you may be able to smell it as well. If you notice this,
get your coolant inspected at the soonest opportunity. Other
potential leak culprits include a bad radiator cap, blocked radiator or
damaged sensor.

Discolored coolant: Coolant color should never change, but it can

when coolant gets contaminated with debris or its been in your car
so long that the additives in it deplete. When coolant color changes
or gets cloudy, bring it to us to see if it needs to be changed.

Engine overheats: Worst-case scenario: your engine can overheat,

seize-up and crack, causing your car to stop completely. If this has
happened, its probably too late for a fluid exchange you may
need a whole engine exchange.

Common Cooling System Problems

Problem

Coolant leaks

Symptoms
Stains at the
leakage point or
puddles on your
driveway.

Causes

Solution

Pressure cap and

gasket defective.

Inspect, wash the

cooling system. If
the cap does not
hold pressure,
replace it.

Leakage within the

core.

Accumulation of
rust or debris within
the cooling system.

Engine
Overheating

Loose or worn
drive belt.

Defective
water
NOTE: Never try to remove a radiator cap when
the engine
is hot.
pump
(bearing failure)

Pressure-test your
radiator and replace
if leaking.
Remove the
radiator cap and
wiping the inside of
the filler neck with
your finger. If you
see grease, rust, or
debris, youll need
to perform a radiator
flush.
Inspect the drive
belt for stretching,
cracks and other
wear and make sure
it has the proper
tension using the

 END