QUALIFICATION : AUTOMOTIVE SERVICING NC II

UNIT OF COMPETENCY : SERVICE CLUTCH SYSTEM

CODE : ALT723310

MODULE TITLE : SERVICING CLUTCH SYSTEM

MODULE DESCRIPTOR : This module deals with servicing clutch system. It also
includes repairing and replacing the damaged
parts/components of the system.

NOMINAL DURATION : 32 Hrs.

CERTIFICATE LEVEL : NC II

PREREQUISITE : Perform Under chassis Maintenance NC I

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module, the trainee/student must be able to:

LO 1. Diagnose clutch failure/problem

LO 2. Pull out and mount clutch component parts

LO 3. Dismantle/Install clutch mechanism

LO 4. Overhaul hydraulic clutch mechanism

LO 5. Perform clutch parts failure analysis

LO 6. Set/Adjust clutch system components

LO 7. Bleed clutch hydraulic system

LO 1. DIAGNOSE CLUTCH FAILURE/PROBLEM

ASSESSMENT CRITERIA:

1. Clutch should engage/disengage engine and transmission smoothly.

2. Work is completed in accordance with company standard operating
procedures and manufacturer’s specification, manuals using specified tools
and equipment.

CONTENTS:

1. Clutch failure/problem diagnosis

a) Clutch pedal goes to floorboard when depressed
b) Clutch slip when engaged
c) Clutch spine or drags while engaged
d) Clutch chatters or grabs while being engaged
e) Clutch related vibration
f) Clutch area noises
g) Clutch pedal pulsation

CONDITIONS:

Students/trainees must be provided with the following:

1. Light duty vehicle

2. Hydraulic lifter
3. Manuals

METHODOLOGIES:

1. Interactive discussion
2. Self-paced instruction
3. Dual training

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Practical demonstration
4. Direct observation
LO 2. PULL OUT AND MOUNT CLUTCH COMPONENT PARTS

ASSESSMENT CRITERIA:

1. Dismounting procedure follows repair manual.

2. Bolts are tightened following correct torque, sequence and pattern
3. Work is completed without causing damage to vehicle or workplace property
and equipment.

CONTENTS:

1. Dismounting and mounting procedures

2. Bolt tightening sequence and pattern, and correct torque
3. Handling of special tools for dismounting & mounting
4. Precaution in handling hydraulic fluids and special tools
5. Apply personal safety procedures

CONDITIONS:

Students/trainees must be provided with the following:

1. Hydraulic lifters/mechanical lifters

2. Support stand
3. Transmission jack
4. Basic hand tools
5. Manuals
6. Light duty vehicle

METHODOLOGIES:

1. Interactive discussion
2. Self-paced instruction
3. Dual training

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Practical demonstration
4. Direct observation
LO 3. DISMANTLE/INSTALL CLUTCH MECHANISM

ASSESSMENT CRITERIA:

1. Similar parts are accurately tagged/marked

2. Damage parts are replaced as per repair manual (pressure plate, clutch disc,
release bearing, pilot bearing)
3. Installation procedure is followed as per manufacturer specification
4. Work is completed without causing damage to any workplace property or
vehicle

CONTENTS:

1. Procedures in dismantling and installing clutch mechanism

2. Tagging/marking of similar parts
3. Replacing damaged parts
4. Use of relevant tools and equipment
5. Apply personal safety procedures

CONDITIONS:

Students/trainees must be provided with the following:

1. Light duty vehicle

2. Hydraulic lifters/mechanical lifter
3. Basic hand tools
4. Manuals

METHODOLOGIES:

1. Interactive discussion
2. Self-paced instruction
3. Dual training

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Practical demonstration
4. Direct observation
LO4. OVERHAUL HYDRAULIC CLUTCH MECHANISM

ASSESSMENT CRITERIA:

1. Worn out rubber cups and O-ring are replaced as per prescribed procedures
2. Master cylinder is scored.
3. Valve checked for damage.
4. Hydraulic clutch mechanism is replaced as per repair manual.
5. Master cylinder, slave, booster is tested as per procedure.

CONTENTS:

1. Procedures in overhauling hydraulic clutch mechanism

2. Procedures in checking hydraulic clutch parts
3. Replacing damaged parts

CONDITIONS:

Students/trainees must be provided with the following:

1. Replacement parts
2. Basic hand tools
3. Manuals
4. Light duty vehicle

METHODOLOGIES:

1. Interactive discussion
2. Self-paced instruction
3. Dual training

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Practical demonstration
4. Direct observation
LO 5. PERFORM CLUTCH FAILURE ANALYSIS

ASSESSMENT CRITERIA:

1. Failure is identified accurately and corresponding repair is recommended.

CONTENTS:

1. Clutch parts failure analysis

CONDITIONS:

Students/trainees must be provided with the following:

1. Clutch parts

METHODOLOGIES:

1. Interactive discussion
2. Self-paced instruction
3. Dual training

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Practical demonstration
4. Direct observation
LO 6. SET/ADJUST CLUTCH SYSTEM COMPONENT

ASSESSMENT CRITERIA:

1. Clutch pedal free play is set as manufacturer’s specification.

2. Clutch finger height is adjusted as per standard.
3. Special service tools are used according to manufacturers manual
instructors.

CONTENTS:

1. Procedures in adjusting clutch pedal free play

2. Procedures in adjusting clutch finger height
3. Use of special service tools

CONDITIONS:

Students/trainees must be provided with the following:

1. Special service tools

2. Basic Hand Tools
3. Light duty vehicle

METHODOLOGIES:

1. Interactive discussion
2. Self-paced instruction
3. Dual training

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Practical demonstration
4. Direct observation
LO 7. BLEED CLUTCH HYDRAULIC SYSTEM

ASSESSMENT CRITERIA:

1. Checking of fluid leakage, level and air lock are performed as per
manufacturer’s manual.
2. Bleeding procedures are performed as per manufacturer’s
instruction/specification.
3. Work is completed without causing damage to any workshop property or
vehicle.

CONTENTS:

1. Checking fluid leakage, level and air lock

2. Bleeding procedure
3. Safety handling of brake fluid

CONDITIONS:

Students/trainees must be provided with the following:

1. Basic hand tools

2. Manuals
3. Light duty vehicle
4. Brake fluid

METHODOLOGIES:

1. Interactive discussion
2. Self-paced instruction
3. Dual training

ASSESSMENT METHODS:

1. Interview
2. Written examination
3. Practical demonstration
4. Direct observation