Cos Modul 7 Clutch Repair

8/21/2019 Cos Modul 7 Clutch Repair

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COURSE OF STUDYAUTOMOTIVE TECHNICIAN (P-119-1)

MODULE 07: CLUTCH SYSTEM REPAIRModul S!"o#$%$:

This module is developed for students to acquire knowledge and skills in clutch system repair. At the end of this module trainees will be able

to :• identify clutch system component location

• service gear shift linkages

• change clutch cable

• service clutch master pump

• service clutch slave cylinder

• conduct hydraulic clutch system bleeding

• remove transmission from vehicle

• rectify clutch assembly

• install transmission to vehicle

Modul O&'%*$:

Carry out clutch system repair using service manual, hand tools set, replacement parts, PP, steel ruler, bleeding equipment, lubricant andfluid, special tools, measuring tools and transmission support so that clutch system component location identified, gear shift linkage removed,gear shift linkage e!amined, gear shift linkage installed, clutch cable removed, clutch cable changed, clutch master pump and clutch slavecylinder serviced, hydraulic clutch system bleeding conducted, transmission from vehicle and clutch assembly removed, clutch assemblye!amine, clutch assembly assembled and transmission to vehicle installed in accordance with manufacturer"s specification.

Modul Co""

T+$, No

#$.#% &ervice gear shift linkages#$.#' (eplace vehicle clutch cable#$.#) (ectify hydraulic clutch system#$.#* (ectify vehicle clutch assembly

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STEPS NO.LED/E PERFORMANCE HRSDELIVERY

MODEASSESSMENT MODE

'. +dentify clutchsystem component

location

'.' Purpose of clutch system'.) ayout of clutch system

component'.* -unction and operation of

clutch system'.' ocate clutch system'.' +nspect functionality of

clutch system

• echanical system

• /ydraulic system

Attitude0&afety

•

1ear PP

)

*

ecture

2emonstration and3bservation

'. 4nowledge 526

). Performance 5A 7 C6• ocate clutch system

• +nspect functionality

of clutch system8 echanical

system8 /ydraulic system

• +nspect functionality

gear shifting linkage

• 2etach gear shift

inkages

• +nspect condition ofgear shift linkages8 9ent8 &tuck8 2amage

• -i! gear shift linkages

• Adust gear linkages

2etach clutchcable

• +nspect condition of

clutch cable

8 9ent8 &tuck8 2amage

• -i! clutch cable

). (emove gear shiftlinkage

).' ayout of gear shiftlinkages

).) Types of gear shifting linkages

• (od

• Cable

).* Procedures of removinggear shift linkage

) ecture

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MODEASSESSMENT MODE

).' 2etermine gear shifting inkage location

• (od

• Cable

).) +nspect functionalitygear shifting linkage

).* 2etach gear shiftlinkages

Attitude0&afety

• ;se fender cover for

safety

* 2emonstration and3bservation

• Adust clutch pedal

free Play• (emove clutch

master pump

• 2ismantle clutch

master pump

• +nspect clutch

master pump components

• Assemble clutch

master pumpcomponents

• (efit clutch masterpump

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MODEASSESSMENT MODE

• (emove clutch slave

cylinder

• 2ismantle clutch

slave cylinder

• +nspect clutch slave

cylinder components

• Assemble clutch

slave cylindercomponents

• -i! clutch slave

cylinder

• 9leed hydraulic clutch

system

• Test clutch for proper

function

*. !amine gear shiftlinkage

*.' -unction of gear shiftlinkage

*.) Procedures of checking

gearshift linkage condition*.' +nspect condition of gear shift linkages

• 9ent

• &tuck

• 2amage

Attitude0&afety

• eticulous when

checking gear linkage

'

)

ecture



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MODEASSESSMENT MODE

8 1ear 8 &coring8 1arping8 2amage

• +nspect clutch release bearing condition

8 >oise8 2amage

• easure flywheel

surface run out

• +nspect pilot bearing

condition8 >oise8 2amage

• -i! clutch assembly

• Adust clutch freeplay

• Attach transmission

to vehicle

?. (emove clutchcable

?.' -unction of clutch cable?.) Techniques of removing clutch cable

?.' 2etach clutch cable?.) +nspect condition of

clutch cable

• 9ent

• &tuck

• 2amage

Attitude0&afety

• eticulous when checking

clutch cable

)

*

ecture


$. +nstall clutch cable

$.' Procedures of installing clutch cable$.) Purpose of pedal free play

$.' -i! clutch cable$.) Adust clutch pedal free

play

Attitude0&afety

• eticulous when

installing clutch cable

'

*

ecture


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MODEASSESSMENT MODE

%. &ervice clutchmaster pump

%.' -unction and operation ofclutch master pump

%.) Construction of clutch

master pump%.* Procedure of servicing

clutch master pump

%.' (emove clutch master Pump%.) 2ismantle clutch master Pump%.* Clean and inspect clutch master pump components

• 1ear and tear

• &cratch

)

*

ecture


%.< Assemble clutch master pump components%.? (efit clutch master

pump

Attitude0&afety

• eticulous in servicing

clutch master pump

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MODEASSESSMENT MODE

@. &ervice clutchslave cylinder

@.' -unction and operation of clutch slave cylinder @.) Construction on clutch

slave cylinder @.* Procedures of servicing clutch slave cylinder

@.' 2etach clutch slave cylinder @.) 2ismantle clutch slave

cylinder @.* Clean and inspect clutch slave cylinder

components

• 1ear and tear

• &cratch

@.< Assemble clutch slavecylinder components

@.? -i! clutch slave cylinder

Attitude0&afety

• eticulous in servicing

clutch master pump

)

*

ecture


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MODEASSESSMENT MODE

. Conduct hydraulicclutch systembleeding

.' Types of clutch fluid.) /ydraulic clutch system

bleeding procedure.' 9leed hydraulic clutch

system.) ;se bleeding tools.* Test clutch for proper

function

Attitude0&afety

• eticulous in bleeding

air from clutch system

'

)

ecture

2emonstration and

3bservation

'#. (emovetransmission fromvehicle

'#.'Types of transmission

• =ear bo! Transmission

•

Transa!le'#.) ocation of transmission'#.* Procedures of removing

transmission assembly'#.' 2etach transmission assembly

Attitude0&afety

• eticulous in handling

heavy component

*

*

ecture


''. (emove clutch

assembly

''.' Types and function of

clutch system''.) Construction and

operation of clutch system''.* Procedures to dismantle

clutch assembly

) ecture

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MODEASSESSMENT MODE

''.' 2etach clutchassembly

''.) 2ismantle clutchassembly

Attitude0&afety

• Avoid scratching clutch

pressure plate

< 2emonstration and3bservation

'). !amine clutchassembly

').' Types and function ofclutch disc

').) Construction andoperation of clutch disc

').* Types and function ofpressure plate assembly

•

&ingle plate dry clutch• 2iaphragm spring

').< Construction andoperation of pressureplate

').? Types and function ofclutch release bearing

').' +nspect friction disc

• -acing wear

• (un out

• 2amage

').) +nspect pressure plate

• 1ear

• &coring

• 1arping

• 2amage

)

<

ecture


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MODEASSESSMENT MODE

').* +nspect clutch releasebearing condition

').< easure flywheelsurface run out

').? +nspect pilot bearingCondition

Attitude0&afety

• eticulous when

measure components

'*. Assemble clutchassembly

'*.' Procedures of fi!ing clutch assembly

'*.' -i! clutch assembly'*.) Adust clutch free play

Attitude0&afety

• eticulous in fi!ing

clutch assembly

'

)

ecture


'


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MODEASSESSMENT MODE

Co A&%l%%$

#'.#< AnalyBe +nformation

#'.#? ;tiliBe the internet to locate and gather information

#*.#@ 2evelop and maintain c cooperation within work group

#


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Sld R"$ +"d Aud%o V%$u+l M+%+l$

REFERENCES AUDIO VISUAL MATERIALS

'. Anthony .&chwaller 5)##: '8

Cos Modul 7 Clutch Repair

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