Clutch system description

CLUTCH SYSTEM DESCRIPTION

The clutch system is a conventional diaphragm type clutch operated by a hydraulic cylinder. The hydraulic system is manufactured from plastic and is sealed for life and can only be replaced in its entirety. The clutch requires no adjustment to compensate for clutch wear.

Hydraulic Clutch

The hydraulic clutch comprises a master cylinder and a slave cylinder connected by a plastic tube. The system comes as a complete assembly, pre filled with hydraulic fluid to ease replacement and minimize repair times. The master and slave cylinders are manufactured from injection moulded thermoplastic which can operate in extremes of temperatures. The hydraulic clutch system is self bleeding.

The master cylinder is mounted in the bulkhead. It locates in a specially designed hole which allows the master cylinder to be installed in the hole at a 45 degree angle from vertical. Once located, the master cylinder is rotated to the vertical position and is automatically secured in this position. The master cylinder has a piston which moves in the cylinder. A rod is attached to the piston and attaches to a spigot on the clutch pedal. A fluid reservoir is mounted on the engine compartment side of the master cylinder and is sealed with a removable rubber cap.

A nylon tube is connected to the master cylinder by a swivel coupling which aids installation and alignment. The other end of the tube is connected to the slave cylinder, also using a swivel coupling. The nylon tube is flexible and allows ease of routing and absorbs engine movements and vibrations.

The slave cylinder comprises a cylinder with a piston and rod. The piston is spring loaded to return to its fully extended position when at rest. A new slave cylinder has the piston locked in the retracted position by a plastic clip. When the clutch is first operated, the hydraulic action of the clutch system breaks the plastic clip and allows the rod to extend. The plastic clip attached to the end of the rod locates in a spherical seat in the release lever. The slave cylinder is located in a bracket which is bolted to the gearbox. A specially shaped slot in the bracket locates the slave cylinder and a plastic clip secures it in position.

Clutch Mechanism

The clutch mechanism comprises a flywheel, drive plate, pressure plate, release lever, release fork and a release bearing. The clutch mechanism is fully enclosed at the end of the engine by a bell housing formed by the gearbox casing.

The spindle of the release lever is located through machined bores in the gearbox casing. The release fork fits on the release lever spindle and is secured to the spindle with a bolt and spring washer. An oil seal is located at the outer face of the gearbox casing and seals against the release lever spindle preventing the ingress of dirt and moisture.

A release bearing is operated by the release fork. The bearing has two lugs which clip onto the forks of the release fork.

The flywheel is bolted to the flange of the engine crankshaft with six bolts. A dowel ensures that the flywheel is correctly located. A ring gear is located on the outside diameter of the flywheel and is seated against a flange. The ring gear is an interference fit on the flywheel and is installed by heating the ring gear and cooling the flywheel. The ring gear is a serviceable item and can be replaced if damaged or worn.