Clutch

Automotive clutch is used to connect and disconnect the

manual transmission from the engine.

Clutch Parts
Clutch release mechanism cable, linkage or
hydraulic system allows the driver to disengage the
clutch when using foot pedal.

Master Cylinder any leak in

the hydraulic system will
prevent the clutch pedal
from coming back up.
Takes brake fluid.

Slave Cylinder

Cable

Clutch Parts
Clutch Fork lever that forces the release bearing
into the pressure plate.

Clutch Parts
Release/throw out bearing bearing that reduces
friction between the clutch fork and the pressure
plate.
Dry or worn bearing will cause a squeal when
stepping on the clutch pedal, worse on a cold day.

Clutch Parts
Pressure plate spring loaded device that
presses the clutch disc against the flywheel.
Two types Coil spring and Diaphragm type.

Clutch Parts
Clutch Disc Friction disc (same material as
brakes) splined to the transmission. There should
never be any oil or grease on the clutch parts.

Clutch facing springs are use to cushion disc

when it engages.

Clutch Parts
Flywheel provides a mounting place for the
clutch and friction disc assembly.
Flywheels are made from hardened steel (brake
rotors).
Ring gear around the flywheel can be replaced.
Grind if cracks (over heating), grooves, or glazed.
Warped flywheel will cause pulsation in clutch
pedal and may grab at acceleration.

Clutch Parts
Pilot Bearing bushing or bearing that supports
the forward end of the transmission input shaft.

Clutch

Clutch Problems
Grabbing clutch vibration or jerking on takeoff.
Cause: Engine mount, friction plate, pressure
plate, flywheel.
Dragging Clutch transmission grind when trying
to shift or engage clutch.
Cause: too much pedal free play, warped or bent
friction disc, oil or grease on the friction disc.
Clutch slippage RPMs go up, but the vehicle
doesnt move.
Cause: Worn friction disc, miss adjustment of the
clutch cable.

Manual Transmission

Manual Transmission
Transmission input shaft a shaft, operated by the
clutch (engine), that turns the gears inside the
transmission.
Transmission Gears provide a means of changing
output torque and speed.
Synchronizers devices for meshing gears into
engagement and prevent grinding.
Shift forks pronged units for moving synchros on

Manual Transmission
Shift linkage arms or rods that connect the shift
lever to the shift forks.
Gear shift lever lever allowing the driver to shift
gears.
Two types Internal and external. If out of
adjustment might cause grinding.
Output shaft shaft that transfers rotating power
out of the transmission to the driveshaft.
Transmission case housing that encloses
transmission shaft, gears, and lubricating oil.
Counter shaft Gears on this shaft are attached to
the output shaft.

Manual Transmission

Neutral
Neutral all the synchronizer sleeves are located
in the center. Input shaft turns and output shaft is
stationary.

1 Gear
st

1st Gear (4.36:1) Synchronizers engage to the first

output gear. Small gear on countershaft drives a
large gear on output shaft giving high torque and low
speed.

nd

Gear

2nd Gear (2.52:1) 1/2 gear synchronizer is moved

away from the first gear and engaged to the second
gear. This provides less torque, but more speed than
the first gear.

rd

Gear

3rd Gear (1.51:1) 3/4 synchronizer is moved to

engage the third gear (1/2 synchronizer is in neutral).

th

Gear

4th gear (1:1) 3/4 synchronizer is moved to engage

the fourth gear. The synchronizer sleeve locks the
input shaft directly to the output shaft. No torque
multiplication.

th

Gear

5th Gear/Overdrive gear (0.87:1) Keeps the

engine speed down at highway speeds to increase
fuel economy.

Reverse Gear
Reverse gear (4.02:1) Synchronizer is moved
onto reverse gear on the output shaft. Power flows
through the counter shaft, reverse idler gear
(changes the direction), reverse gear, and to the
output gear. Reverse light switch is engaged at the
same time.

Manual Transmission

Transmission Gear oil

Takes 80W 90W, also called synchro oil.
If low on oil, might cause noises.

Speedo meter Gear

r (worm) is attached to the output shaft to drive the Speedo