What to Keep in Mind When Assembling the Clutch
Clutch assembly is not an easy task that
requires time and perseverance. To avoid frequently needless and expensive
replacement of the whole unit, prior estimation is a must. In such cases, ZF
Aftermarket is eager to share its solid experience in the transmission repair
with the repair shops, helping to prevent errors specifically related to clutch
plate mounting.
The clutch is a connecting link between the
engine and gearbox – and one of the most wear-resisting elements. The clutch
can get out of order for many reasons. For instance, the clutch is frequently
exposed to high loads due to towing/driving with a trailer or a defected engine
control unit. However, if the clutch unit does not operate properly that does
not necessarily mean that you are instantly doomed to pay for replacement of the
whole unit. ZF Aftermarket experts recommend repair shop technicians to
carefully inspect the adjacent elements in case of clutch malfunctions –
including the clutch engagement and the seals of the engine, flywheel, and
gearbox. Repair professionals often use the Sachs clutch kit in this instance
as it contains all the required components for a fast and safe repair.
Sachs clutch kit
Clutch examination before assembly
The clutch must be quite durable and
heat-tolerant, because the operation under severe loads may cause abrasive
wear. Sachs ZF specialists recommend using Sachs clutch plates which conform to
top quality standards and are also tested for clearance.
However, nothing is
perfect and it would be reasonable to check the state of the package and the new
clutch before installing it, as it may have been broken during shipping or
because of incorrect handling. To be certain that the new part is in good
running order ensure that the lateral run-out of the clutch plate is limited to
0.5 mm. If the allowed value is exceeded, this issue can be solved with the
help of a straightening fork, which is included in the Sachs lateral run-out
tester.
Mounting position and clutch centering
The correct positioning of the clutch unit during installation is a key to successful repair service. The clutch misplacement may lead to the breakdown of the clutch itself, its hub spline, clutch toggle lever, or even the gearbox. The installation instructions can be commonly found on the component side. Another simple solution is to compare the new clutch with the old one before mounting.
The new clutch must be accurately centered to
avoid any problems with the hub spline. It is crucial to comply with tolerance
limits between the gearbox input shaft and the hub spline, because even the
slightest incorrectness exceeding the allowable limits (only a few hundredths
of a millimeter) during installation of the input shaft can later prevent the
mobility needed for the clutch release. The hub spline must freely slide onto
the gearbox shaft.
Hub spline lubrication (greasing)
ZF experts advise lubricating the hub spline with Sachs advanced lubricating materials. Thanks to its viscosity and heat endurance the lubricant sticks to the spline while operating without spreading. To avoid clutch judder when the clutch is later released, surpluses of lubricating materials must always be eliminated, and the clutch linings must be kept clean .
Products in OEM quality
To ensure enhanced reliability and running characteristics, ZF specialists encourage technicians of repair shops to use top-quality spare parts in maintenance and repair of the powertrain components. Therefore, it is reasonable to pay attention Sachs clutch products, manufactured with the help of quality materials and thoroughly tested in accordance with the highest standards. Sachs repair kits are ideal solutions for professional repair shops, as they contain everything you need to provide top-quality repair services.
