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Service Clutch System
Service Clutch System
Service Clutch System
AUTOMOTIVE
QUALIFICATION
AUTOMOTIVE NC II
UNIT OF COMPETENCY
MODULE TITLE
SERVICING CLUTCH SYSTEM
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
Performance Criteria Checklist
Operation/Task/Job Sheet
Answer Key
Learning Experiences
Information Sheet
Module Content
List of Competencies
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL
This material is provided to guide each trainee for easy understanding of visual graphics design.
The module contains training guide and activities for the 7th core competency of
“AUTOMOTIVE NC II”. The module title is “Servicing Clutch System”.
Service Clutch System- This unit deals with the skills, knowledge and attitude required in
servicing. You need to provide and study those materials for you to complete the core modules
You are required to go through a series of learning activities in order to complete each learning
outcomes of the module. For further readings, go through with the information sheets
provided in this learning material, other reference materials and resource sheets are also
included here as an additional guide. Activity sheets and job sheets are provided for your
own tests, researches and experimentations. It includes also self-check tests to answer for you
to easily measure your understandings about the topics.
Compare your answers honestly in the answer key provided to know the result. If you have
questions, please do not hesitate to ask your facilitator for assistance.
You may also have some or most of understanding or knowledge and skills covered in
this module because you have:
• Been working for some time.
• Already completed training in this area.
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
If you can show evidence or demonstrate to your trainer that you are competent in a
particular knowledge or skills, ask him/her about having formally recognize so you will not
have to do some training again. You can provide or show certifications to qualify for a certain
competency from previous training as evidence. If the skills you acquired from previous
learning are still relevant to the module with a certification showing evidence that you are
competent, these can be part of your RPL.
Last part of this learning material is a learner’s diary. Use this diary to record an
important dates and jobs undertaken from other workplace of events that will assist you in
further details need by your trainer or assessor. A Record of Achievement is also provided
for your trainer to complete this module of training.
This learning material was prepared to help you achieve the required competency in
Servicing clutch system”. This will be the source of information for you to acquire
knowledge and skills in this particular trade, with minimum supervision from your trainer.
1. Ask your trainer on how you will both organize the training session. Read and
understand thoroughly the learning guide. It is divided into sections which
covers all the skills and knowledge you need to successfully complete this
training.
2. Work through all the information and complete the activities in each section.
Read information sheets and complete the self-check. Suggested references are
included to support your understandings.
3. You can ask guidance from your trainer as you go along the training to
determine whether you are in a right track.
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
4. Your trainer will tell you the important consideration as you go along with the
activities. Listen and take note those important things.
5. You will be given an opportunity to ask questions and practice on the job.
6. Answer the self-test questions at the end of each section to test your own
progress.
7. Ask your trainer to assist you and evaluate your work after each activity. This
is also for you to get some ideas how you are going to improve your work. A
feedback is always provided by your trainer for you to improve your skills.
Ask a written feedback from your trainer for each activity you work-out for
your own progress. Your trainer keeps feedback / pre-assessment reports as
reference.
8. When you are already finished with the training and through with the activities
provided in this competency-based learning material and feel confident that
you have now sufficient knowledge and skills, your trainer will arrange and
appoint with a registered competency assessor to assess you. The result of the
assessment will be recorded in your Competency Achievement Record.
AUTOMOTIVE NC II
COMPETENCY-BASED LEARNING MATERIALS
List of Competencies
BASIC COMPETENCY
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
Unit of Competency
No. Module Title Code
COMMON COMPETENCY
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
1 Apply appropriate Applying ALT723201
sealant/adhesive appropriate
sealant/adhesive
2 Move and position Moving and ALT723202
vehicle positioning
vehicle
3 Perform Performing ALT311202
mensuration and mensuration and
calculation calculation
4 Read, interpret Reading, ALT723203
and apply interpreting and
specifications and applying
manuals specifications and
manuals
5 Use and Apply Using and Applying ALT723204
Lubricant/Coolant Lubricant/Coolant
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
12 Provide work skill Providing work ALT311209
instructions skill instructions
CORE COMPETENCY
Testing and
Test and Repair
Repairing ALT723305
3. Wiring/Lighting
Wiring/Lighting
System
System
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
Service Engine Servicing Engine ALT723309
6.
Mechanical System Mechanical System
9.
ALT723312
Service Servicing
Steering System Steering System
10.
ALT723314
Service Brake Servicing Brake
System System
11.
ALT723315
Service Servicing
Suspension System Suspension System
Preventive Preventive
Maintenance Maintenance
13.
ALT723313
Overhaul Overhauling
Manual Manual Transmission
Transmission
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
MODULE CONTENT
ASSESSMENT CRITERIA:
3.1 Worn out Rubber cups and “O” rings replaced as per prescribed procedure
LEARNING EXPERIENCES
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
• Read Information Sheet # 3.7- • Perform all activities required.
1 on 3.7-1 to 3.7-4 about
Diagnose clutch • You must get a rating of 80 to
failure/problem, Pull-out and 100%. If you get below 80%
mount clutch Component
rating, go over the same activities.
parts, Overhaul hydraulic
clutch mechanism, Perform If you get the required rating,
clutch parts failure analysis, proceed to next activities.
Set/Adjust clutch system
components, Bleed clutch
hydraulic system.
• Answer Post Assessment in
• Sheet 3.7-1 to 3.7-4
• Compare your answers to
answer Key Sheet 3.7-1 to
3.7-4
• Observe the demonstration
on “Clutch systems,
Manuals, Company
standard operating
procedure, Tools and
equipment, Clutch
failure/problems.
• Perform the Performance
Task Sheet 3.7-1 to 3.7-4
• Evaluate the demonstration
using the Performance Task
Rubrics
• 3.7-1 to 3.7-4
Contents:
• Competency must be assessed on the job or simulated environment.
• The assessment of practical skills must take place after a period of supervised
practice and repetitive experience.
.
.
Assessment Criteria
Conditions
Assessment Method:
• Interview
Learning Experiences
Learning Outcome 3.7
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
SERVICE CLUTCH SYSTEM
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
Perform Task Sheet # 3.7.1 to 3.7- Evaluate the demonstration of task
4. using the Performance Criteria Checklist
# 3.7.1 to 3.7-4. Have your trainer
evaluate your performance
PRESENTED
Learning Objectives:
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
Introduction
The service clutch system is a critical component within the drivetrain of automotive
vehicles, particularly those with manual transmissions. Its primary function is to engage
and disengage the power flow between the engine and the transmission, allowing for
gear changes and smooth operation of the vehicle. This system plays a pivotal role in
controlling the transfer of power from the engine to the wheels, ensuring efficient
performance and maneuverability.
Modern service clutch systems are designed with precision engineering to withstand
high levels of torque and repeated engagement cycles. They consist of several key
elements, including the clutch plate, pressure plate, release bearing, and clutch pedal
assembly. When the driver depresses the clutch pedal, hydraulic or cable actuation
systems disengage the clutch, temporarily interrupting the power transfer. This action
enables the driver to shift gears seamlessly without causing damage to the transmission
or drivetrain components.
Regular maintenance and inspection of the service clutch system are essential to
ensure optimal performance and longevity. Over time, clutch components can wear out
due to friction and heat generated during operation. Signs of a failing clutch system may
include slipping, difficulty shifting gears, or a spongy clutch pedal feel. Addressing these
issues promptly through clutch adjustments or component replacements can prevent
costly repairs and downtime.
Assumptions
Safety Considerations
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
• Ensure the clutch system works well to avoid accidents.
• Some vehicles have safety features that require the clutch to be fully depressed
before starting.
PRE-TEST
FILL IN THE BLANKS
Direction: Answer the following questions or complete the statements by writing the appropriate words
or amounts in the answer blanks.
Performance objectives:
STEPS:
1. Prepare: Gather tools, lift the vehicle, and drain hydraulic fluid.
2. Remove Components: Disconnect and remove master cylinder, slave cylinder, and
hydraulic line.
3. Inspect: Check components for wear, damage, or leaks.
4. Clean and Lubricate: Thoroughly clean and lubricate components.
5. Reassemble: Install new or refurbished components and connect hydraulic line.
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
6. Bleed System: Fill with fresh fluid and bleed to remove air bubbles.
7. Test: Check clutch operation, adjust if needed, and test drive.
8. Finalize: Adjust pedal play, check fluid levels, inspect for leaks, and clean up.
INFORMATION SHEET
The clutch system is a very important part of the transmission system. The clutch transfers the
power from the car’s engine to the transmission system using a complex mechanism. If you are
using a manual transmission car, the clutch when operated will created sync the engine and the
transmission system. When your foot is off the clutch pedal, the pressure created operated a
hydraulic mechanism, which connects to the engine flywheel and thereby transmitting the
motion to the wheels. Your cars clutch basically connects two shafts, locking them to make both
shafts spin at the same speed. It is because of the clutch you can stop the car without stalling the
engine.
Clutch disc
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
The purpose of the system revolves around one component, the clutch disc. A large round disc
typically more than 30 cm in diameter, it slides onto the transmission’s input shaft. On both flat
surfaces is bonded friction material that’s commonly semi-metallic like brake pads. When the
clutch pedal is pressed, it spins freely and no power transfers between the transmission and
engine. When the clutch pedal is released, it is squashed between the flywheel and the clutch
pressure plate to match the transmission’s rotation with engine speed.
The clutch pressure plate is on the opposite side of the clutch disc from the engine. Its purpose is
to release pressure from the clutch when the pedal is pressed. Metal fingers in the middle are
actually springs that, when pressed together, lever a pressure disc away from the friction
material.
Flywheel
The flywheel is bolted securely to a flange at the rear of the engine’s crankshaft. It’s a heavy
steel plate that performs a few roles. First, it’s a weighted mass that minimizes vibration by
balancing the engine’s rotation. As well, the flywheel smooths the engine’s RPMs up and down
to make engaging the clutch less jerky. Its main purpose is for the friction material on the clutch
disc to lock against, letting the transmission carry away the power the engine produces.
The pressure plate is spinning at the same rate of rotation as the engine, and a stationary part
need to engage it to release pressure from the clutch when needed. That’s the job assigned to a
release fork and release bearing. When the clutch pedal is depressed, it extends a rod at the
transmission to press against the release fork. In turn, the fork uses lever motion to press toward
the fingers of the clutch pressure plate. A release bearing at the end of the clutch fork allows the
non-rotating fork to release pressure, disengaging the clutch.
Slave cylinder
The clutch slave cylinder has a single purpose. When activated, a rod extends from the slave
cylinder to press against the release fork. Typically, the slave cylinder is hydraulically operated
although in some instances it could be cable operated as well.
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
Master cylinder
In clutch systems that use hydraulic pressure, a master cylinder is a crucial part. It’s mounted to a
car’s firewall directly opposite the clutch pedal. When the pedal is pressed, a piston in the master
cylinder compresses fluid into the hydraulic line toward the slave cylinder. That fluid pressure
activates the slave cylinder and so on. When the pedal is released, fluid returns to the master
cylinder and the clutch disc re-engages.
Clutch pedal
From inside your car, the only clutch component you can visually recognize is the clutch pedal.
It leverages the energy from your foot pressing on it to move the piston in the master cylinder. A
heavy spring on the clutch pedal is used to return it to the top of its travel when you lift your
foot.
Pilot bearing
While not exactly a clutch part, the pilot bearing is included because it should be replaced when
changing the clutch. It’s a small ball bearing or needle bearing assembly that fits perfectly into
the end of the crankshaft. The transmission input shaft fits into the center of the pilot bearing,
both centering the transmission and clutch and stabilizing the transmission with the engine.
POST-TEST
ENUMERATIONS
1.
2.
3.
4.
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
5.
6.
7.
8.
ANSWER KEY
PRE-TEST
1. Drivetrain
2. Engine
3. Torque
4. Bearing
5. Pedal
6. Longevity
7. Gears
8. Costly
9. Gear
10. Driving
POST-TEST
1. Clutch disc
2. Clutch pressure plate
3. Flywheel
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA
4. Release fork/release bearing
5. Slave cylinder
6. Master cylinder
7. Clutch pedal
8. Pilot bearing
https://www.trodo.com/blog/parts-of-a-car-clutch-system-and-how-they-function
https://www.linkedin.com/pulse/importance-clutch-your-cars-transmission-system-
ahsan-kamal?trk=articles_directory
DATE DEVELOPED:
DOCUMENT NUMBER:
May 2024
AUTOMOTIVE NC II AUTOMOTIVE-NC-
DATE REVISED:
ALT723310
June 2024
DEVELOPED BY: CHECKED BY:
CHRISTOPHER JAMES A. ARAGONA