Clutch kits and components from DT Spare Parts
“Put the pedal to the metal” is easy to say, but issues with the clutch can soon start causing the driver problems – as Diesel Technic’s Parts Specialists, Lars and Kevin, have highlighted in a recently released video explainer.
In the complex workings of a commercial vehicle, the clutch plays a pivotal role, says Diesel Technic: its primary duty is to transfer the engine’s torque to the transmission seamlessly, ensuring maximum efficiency. Additionally, the clutch must adeptly disengage the engine from the transmission and the broader drivetrain whenever necessary.
In their recent PS Tips video on clutch kits and components, which is available via the Diesel Technic Group YouTube channel, Lars and Kevin explain the structure of a clutch and the special features to look out for.
They show various components and the installation directly on the truck to demonstrate how it works in practice. In particular, they look at the clutch cover, the clutch disc and the flywheel, and also analyse common types of defects at the end of the video.
“During the shifting operation, the clutch disc and flywheel are separated from each other so that contact is interrupted and the shifting operation can be performed. The clutch disc sits between the clutch cover and the flywheel,” said Diesel Technic.
“Thanks to its torsional dampers, it is able to absorb large forces and ensures a smooth switching operation. During removal of the clutch cover, make sure that the screws are loosened crosswise so that the disc springs can relax evenly. This prevents a displacement of pressure.
“When checking disc springs, one of the things to pay attention to is the contact pattern, as this represents the contact surface of the drive plate.
“It is clear that there are many individual components on the clutch and that they are interlinked. Here Diesel Technic brand, DT Spare Parts is a strong partner with over 900 products and a large selection of brands.
“The brands included are DAF, Ford, Iveco, MAN, Mercedes-Benz, Scania and Volvo. In the Partner Portal of Diesel Technic, clutch discs, oil seals, flywheel gears, various clutch kits and many other add-on components can be purchased.”
Another component of the clutch is the flywheel. In the video, Kevin explains that “a blue colouration indicates thermal overload”. The constant friction on the spare part can change the material properties and restrict its functionality.
If the flywheel is replaced and installed, says the firm, particular attention must be paid to the screws.
“Depending on the manufacturer’s specifications, these must be replaced or can be reused. A dimensional check is always recommended.
“To install the flywheel, two centring sleeves are attached to ensure correct positioning. The screws for fixing are tightened in the order specified for the vehicle. Make sure that the prescribed angle is observed when tightening the bolts.”
Parts Specialist Kevin gives the tip to mark the bolts with a pencil so that they can be brought into the same direction of alignment.
In the second step, explains the company, a centring pin is used to install the clutch disc. Once this has been inserted, two mounting bolts are used to attach the clutch. The remaining bolts are then screwed crosswise again in the tightening sequence specified by the manufacturer and to the correct torque.
“Before tightening, it is very important to check that the clutch and clutch disc are correctly positioned on and in the flywheel,” says Lars.
At the end of the video, Lars once again points out various potential clutch faults in order to avoid any problems for his workshop colleagues – as he knows that when installing the clutch disc, it often happens that it is incorrectly centred or the gearbox bumps against it.
With regard to greasing, this should only be done if “it is expressly requested by the manufacturer, otherwise it leads to sluggishness and malfunctions,” explains Lars.
In the area of the release mechanism, says Diesel Technic, check for damaged components and grease leaks or overuse. There may be several indications on the clutch disc as to the exact fault. Torsion dampers and abrasion caused by thermal overload can be quickly recognised by a professional. Marks from screws on the flywheel indicate incorrect installation or an improper torque.
“The clutch is often not adjusted at all or adjusted incorrectly. If a new clutch is installed, however, the parameters must be adjusted to ensure that the control units work correctly,” adds Parts Specialist Kevin.
On technical questions, the Diesel Technic Parts Specialists’ Helpdesk can provide additional support.
