DJJ6153 ;

MECHANICAL COMPONENTS AND MAINTENANCE PROGRAM

CLUTCH AND BRAKE
Present by ;
AMINUDDIN BIN MAHALI 09DKM15F1021
RAZIRIE BIN ASNUH 09DKM15F1028
MUHAMMAD SHUKRI BIN ABU HURERA 09DKM15F1003
NORRAFIUDDIN BIN MOHAMAD YUSOF 09DKM15F1036
YOOT ZI HAO 09DKM15F1806
YAP YEONG SHENG 09DKM15F1808

LECTURER ; EN.HASRY BIN ABDUL SAMAD

DEFINITION OF CLUTCH

A clutch is a mechanical device that provides for the transmission of

power (and therefore usually motion) from one component (the driving
member) to another (the driven member) when engaged, but can be
disengaged.
FUNCTION OF CLUTCHES
i. To separated the and make it easier to enter the gear
ii. To justify the guide that connect and decided the power engine gear box.
iii. Used for reunite and uninstalling an coupled engine (fly wheel) and conducting
(gear box)
iv. Can control speed down or climb a hill
CLUTCH PRINCIPLE
It operates on the principle of friction. When two surfaces are brought in
contact and are held against each other due to friction between them,
they can be used to transmit power. If one is rotated, then other also
rotates. One surface is connected to engine and other to the transmission
system of automobile. Thus, clutch is nothing but a combination of two
friction surfaces.
 THE FUNCTION OF CLUTCH:

I. Easy to exchange gear.

II. Allowing the vehicles to move smooth.
III.To enable the engine operating while stops without putting the
gear in natural position.
IV.To connect and disconnect the flow of energy from engine to the
delivering power.
 MAIN COMPONENT OF CLUTCH:
Clutch cover PRESSURE PLATE Clutch Plate Flywheel

Throw-Out Bearing Release Lever/ Fork COIL SPRING/ DIAPRHAGM

TYPES OF CLUTCH:

1. Cone Clutch
2. Single plate clutch
3. Multi-plate clutch.
4. Semi-centrifugal clutch.
5. Centrifugal clutch.
6. Disk Clutch.
 Cone Clutch

The cone clutch consists two cones , one internal cone fixed to
the driven shaft and another cone fitted on the driven shaft.

The operating lever used only for disengagement of the clutch.

The main advantage of cone clutch over the disc clutch is very
simple and required less axial pressure to disengaged the clutch.
Cone Clutch
 Single Plate Clutch

In the single plate clutch a flywheel is fixed to the engine shaft and a
pressure plate is attached to the gear box shaft.
This pressure plate is free to move on the spindle of the shaft.
A friction plate is situated between the flywheel and pressure plate.
Some springs are inserted into compressed position between these plates.
When the clutch pedal releases then the pressure plate exerts a force on the
friction plate due to spring action.
So clutch is in engage position. When the driver pushes the clutch pedal it
due to mechanism it serves as the disengagement of clutch.
Single Plate Clutch
 Multi-Plate Clutch
Multi-Plate clutch is used when large torque is to be transmitted. Example ;
Motor, car and machine tools.
Multi-Plate clutch is used when compact construction is require. Example ;
Scooter and motor cycles.
For the clutch disengagement, the end plate is withdrawn to compress the
springs and release the other plates.
In this arrangement it is difficult to ensure the disengagement of all plates.
To overcome this problem the plates are fitted with small springs to push
the plates apart.
Generally wet type clutch is used in automatic gearboxes, and is operated
by a piston governed by hydraulic pressure.
Wet type clutches are usually used in lates motorcycles.
Multiplate clutch
 Semi-centrifugal clutch
Semi centrifugal clutch:
Springs are designed to transmit the torque at lower engine speeds.
Centrifugal force assists in torque transmission at higher engine speeds.

Disadvantages of centrifugal clutch:

Automatically disengaging at low engine speeds.
Only at high speeds, centrifugal force is sufficient to keep the clutch in
engaged position.

Advantages of semi centrifugal clutch:

Less stiff clutch springs are used as they operate only at low speeds.
Driver will not get strained in operating the clutch.
Semi-centrifugal clutch
 Centrifugal clutch
It consists of a number of shoes on the inside of a drum or rim of the
pulley.
The upper surface of the shoes are covered with a friction material.
The spider is fitted on the driving shaft.
When centrifugal force is equal to spring force, the shoe is just
floating. But, when centrifugal force higher than the spring force, the
shoes moves outward and comes into contact with the driven member and
pressure against it.
The increase of speed causes the shoes to press harder and clutch
transmit more power.
Centrifugal clutch
 Disc Clutches

This type of clutch consists of two flanges, one flange is

rigidly to the driving shaft and other flange fitted to the driven
shaft.
Single disc clutches are used in automobiles.
When large torque transmission is required the multi disc
clutch are used.
Multi disc clutch has more number of contact surfaces discs
on driving and driven shaft.
Disc clutches
CLUTCH SERVICE AND SAFETY PRECAUTIONS:

Precautions when servicing the clutch.

- Always wear eye protection.

- Remove asbestos dust with approved liquid cleaning system.
- Never use compressed air or a brush to clean off asbestos dust.
- raised and supported the vehicle with jack stands during work under it.
- Use jack stands to support the engine and transmission.
- Set the emergency brake securely and place the gearshift in neutral.
- Avoid touching hot engine and exhaust system parts.
 How to Change a Clutch
Step 1 Put Your Car in a Secure Position
Step 2 Get the Transaxle Ready for Removal
Step 3 Unbolt the Engine Mount
Step 4 Remove the Clutch and Repair the Flywheel
Step 5 Replace the Damaged Clutch
Step 6 Reinstall the Transaxle
Step 7 Release the Jack and Lower Your Vehicle
Step 8 Test the New Clutch
CLUTCH MAINTENANCE:
Simple steps can insure a good performing clutch when the chips are down.

Step 1

- Never let your clutch get wet with water.

Step 2

- Remove main component from the clutch and remove all dust and particles from
it.

Step 3

- Wash out the bell and sprocket assembly. When the parts are clean, dry with
compressed air to prepares for reassembly. Taking one drop of a heavy weight oil
into the needle bearing thoroughly to distribute.(Excess amounts of oil will cause
slipping)
Step 4

- Before assembling, check the air gap between the internal plates of the clutch center
section.(0.032 to 0.038 air gap as optimal.) when the clutch is work, wear is increasing
as high gaps cause elevated engagement speeds and erratic jerking and snapping that
can lead to further damage and poor starts.

Step 5

- the flat thrust bearing inside the clutch should NOT be lubricated and Run this
bearing dry, any oil here will find its way to the plates, and create problems.
PROBLEMS LEADING TO PREMATURE CLUTCH FAILURE
AND PREVENTATIVE MEASURES:

1. Poor lubrication of bushing: Oil the clutch frequently.

2. Riding the brake and gas pedal simultaneously: One or the other never both together,
this generates too much heat and vaporizes the oil in the bushing.

3. Short stop and go runs: The longer the run, the easier it is on the clutch.

4. Chain too tight: Chain should have some flex to it is ideal.

5. Misalignment of sprockets: Clutch and rear drive sprocket must be on the same exact
plane.
Slipping:
cause by,
- oil soaked on driven disc/driven plate over heat

Correction
- adjust/Install new disc and correct leak at its source/replace when necessary

Noisy:
cause by,
- worn release bearing/bearing loose in crankshaft

Correction
- reinstall/replaced bearing
BRAKES
 What is Brake?
A brake is a mechanical device which produces frictional resistance against moving
machine member, in order to slow down the motion of machine.
In the process of performing this function, the brake absorbs kinetic energy of moving
member and the brake absorbs potential energy of lowering member.
The energy absorbed by brakes is released to surrounding in form of heat.

Brake Principal

A brake is a mechanical device that inhibits motion by absorbing energy from a moving
system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its
motion, most often accomplished by means of friction.
 TYPES OF BRAKES?
Disc Brakes: A friction system using a wheel brake to slow the rotation of the automobiles
wheels; brake pads are pushed against the brakes rotor with a set of calipers

Drum Brakes: A friction system using a set of shoes or pads to press against a brake drum

Antilock Braking System (ABS): an electrical control unit, hydraulic actuator and individual
wheel speed sensors that work together to prevent brakes from locking up when they are
slammed on by rapidly pumping brakes when a potential lockup is detected; each wheel is
controlled individually to maintain traction

Air Brakes: a system using air instead of hydraulic fluid to activate a standard disc or drum
brake, usually used in buses, trucks and trailers

Advanced Emergency Braking System (AEBS): an autonomous safety system that employs
sensors to monitor a vehicles proximity to others in the vicinity and automatically applies
emergency braking mechanisms to avoid an imminent collision.
DIFFERENT BETWEEN BRAKE DRUM VS BRAKE DISK:
Brake Drum
They were called drum brakes
because the components were
housed in a round drum that
rotated along with the wheel.
Inside was a set of shoes that,
when the brake pedal was pressed,
would force the shoes against the
drum and slow the wheel. Fluid
was used to transfer the movement
of the brake pedal into the
movement of the brake shoes,
while the shoes themselves were
made of a heat-resistant friction
material similar to that used on
clutch plates.
Brake Disc
Though disc brakes rely on the same
basic principles to slow a vehicle
(friction and heat), their design is far
superior to that of drum brakes. Instead
of housing the major components within
a metal drum, disc brakes use a slim
rotor and small caliper to halt wheel
movement. Within the caliper are two
brake pads, one on each side of the rotor,
that clamp together when the brake
pedal is pressed. Once again, fluid is
used to transfer the movement of the
brake pedal into the movement of the
brake pads.
Brake Drum
Brake Disk
 Advantages
Brake drum Brake disk
The maintenance is easier Disc brakes have much higher mechanical
advantage
Production and purchase costs are Disc brakes grab better when wet
cheaper
You can use them with disc brakes. Disc brakes can be allowed to heat up to
a much higher temperature without any
risk of blowing a tire off a rim

Disadvantages
Brake drum Brake disk
It can collect water. Disc brakes require the wheels to be
dished, which leads to a weaker wheel
It experiences brake fade faster Disc brakes are heavier
It heats up more quickly Brake pad replacement on disc brakes are
more involved, and harder to do in the
field.
Brakes maintenance:

1. Check the power of braking of four wheels with brakes meter and the
effectiveness of circuit.
2. Check the level brakes fluid and replace it if necessary.
3. Check often to the brakes pads because it will blunt because of its hardness
and lifestyle.
4. Change the brakes shoes for every 4changes of brake pads.
5. Check the car's headlight and brakes light are working properly.
6. Do not modify the original brakes system.
Safety precautions in brakes maintenance

1. Using the proper tools and procedures during brake system service.
2. Make sure the tools are in good condition.
3. Handle the asbestos in proper ways.
4. Make sure the car in stabilize conditions before start the brake system service
5. Make sure the equipment used in maintenance is ready such as goggles , safety shoes,
gloves and others.
Symptom of brakes failure:
1. Car is slowing - little brake liquid , braked pads are worn, disc are worn
2. Brake hard - problem in servo brake
3. Car is slow down and loss liquid badly - brake pump in poor condition
4. Brake pedal is soft - air in circuit is introduced , little brake liquid

Common Brakes failure and correction:

1. Low brake fluid - replace the defective component
2. Low brake pedal - adjust the rear drum brakes
3. Spongy or soft brake pedal - bleed all of the brake lines using the sequence recommended for
the vehicles.
4. Excessive brake pedal travel - pumping the pedal when applying the brake ( Diagnosed and
fix the problem )
5. Scraping noise from brakes - rotors or drums are need to resurface or replaced ( Lifetime is
over )
Step of Brake Maintenance ( Disassembly and Reassembly )
Disassembly:
1. Check the pushrod stroke per CVSA checking procedures at 90 to 100 psi reservoir pressure -
alert for problem that need to fix
2. Check each for end play and oil seal leakage before pulling the wheels.
3. Inspect all shoes for even wear - component need to corrected before reassembly ( if brake is not
always worn)
4. Inspect lining surface for heat checking - excessive hear will lead to brake of all wheel not
evenly
5. Check lining wear across each shoe - uneven pattern or excessive grooves show the drums have
to replace
6. Inspect lining surface for grease or oil - Do not reuse a grease or oil-soaked brake shoe.
7. Inspect drum surface for even wear, glazing and heat checking
8. Check s-cam for wear at the inner and outer bushing surfaces, s-cam head and spline areas.
9. Make sure the brake adjusters in proper settings and operation.
10. Check the wear difference between the front and rear axle shoes - air timing imbalance/different
rated friction material if wear is not equal
11. Inspect spiders - Special attention to component (anchor pin-hole area,squareness,s-cam
bushing bore anchor surfaces that not replaceable)
Reassembly:
1. Choose and install the correct material and shoe.
2. Often replace all shoe attaching parts, anchor pin bushings, cam bushings and oil seals.
3. Lubricate anchor pins, brake rollers and bushing area of camshafts - never lubricate the face of roller
4. Install new drums if necessary - mix in light and heavy-duty drums will lead to uneven brake shoe
wear
5. Lubricate axle spindle to ensure bearings slide on easily - ensure the proper hub oil/bearing gease
6. Adjust all brake adjusters on all wheels of the vehicle often - manual (.015 drum) and automotic (.018-
.025)
7. Check all brake hoses leading to chambers - replacing if cracks are found.
8. Check all spring brakes for center seal leakage - replacing if needed.
9. Check brake release - if slow in trailer, quick-release gladhand on the service side of the trailer is
installed to speed up the air exhaust
10. Check spring brakes for proper installation of rubber dust plug in release tool hole.
11. Do not replace different sizes of brake chambers in a vehicle ( long stroke with standard stroke
chamber )
12. Relining a trailer - replace both gladhand seals.
13. Road test after reassembly - check for satisfactory brake performance.
14. Re-examine wheels for excessive end play.
15. Re-check brake adjusters and chambers - proper and equal stroke.
 Anti-Lock Braking System

An anti-lock braking system or anti-skid braking system (ABS) is an automobile

safety system that allows the wheels on a motor vehicle to maintain tractive contact
with the road surface according to driver inputs while braking, preventing the wheels
from locking up (ceasing rotation) and avoiding uncontrolled skidding. It is an
automated system that uses the principles of threshold braking and cadence
braking which were practiced by skilful drivers with previous generation braking
systems. It does this at a much faster rate and with better control than many drivers
could manage.
ABS generally offers improved vehicle control and decreases stopping distances on
dry and slippery surfaces; however, on loose gravel or snow-covered surfaces, ABS can
significantly increase braking distance, although still improving vehicle steering
control.
Anti lock brake System (ABS)
CLUTCH AND BRAKE MAINTENANCE PROCEDURE:

Improper adjustment of clutch or brake

- Follow the manufacturer's adjustment procedures

Contaminant on friction surfaces

- Clean or replace the surface

Out of friction between components

- Check the components and replace if necessary
Worn linkage in engaging clutch or brake
- Check for obstruction and corrosion on moving parts and replace if necessary.

Too much torque

- Replaced part to increased torque loads.

High-frequency cycling
- Replaced with greater heat-dissipation ability.
- Shorten the slipping time during start-up.
References:

- Automotive chassis system by james d.halderman.1996 ,prentice-hal,inc.

- http://www.edwardslawok.com/types-of-auto-brakes.html
- www.slideshare.net
- http://www.akebono-brake.com/docs/pdf/akebono_report_2016en_08.pdf
- http://www.carkipedia.com/clutches/clutch_maintenance.php
- http://chasenracenillustrated.com/pdf/tech/grassroots/oct07_gtb.pdf
- http://www.primelinepe.com/tech-tips-clutch-maintenance/
- https://prezi.com/43po5wtlejpm/clutches-and-brakes-mechanical-component-and-maintenance/
- https://www.g-w.com/pdf/sampchap/9781605252131_ch07.pdf
- http://www.truckinginfo.com/channel/maintenance/article/story/2015/07/haldex-tech-tip-
recommendations-for-complete-brake-maintenance.aspx
- http://www.smartmotorist.com/car-accessories-fuel-and-maintenance/checking-and-maintenance-of-car-
brake-system.html
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- http://144.162.92.233/faculty/mwhitten/presentations/1310/brakesafety.pdf
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and-maintenance-precautions/