Clutch diagram for Hyundai Getz. Adjusting the clutch pedal with your own hands - how to properly adjust the clutch. When clutch adjustment is needed

PERFORMANCE ORDER

1. Measure from the front of the pedal to the carpet. Press the clutch pedal with your hand until a tangible resistance appears and measure the amount of free play. Clutch pedal free travel: 1-3 mm 2. If the free travel of the clutch pedal does not correspond to the required value, adjust it as follows: - loosen the lock nut and, turning the bolt, adjust the free travel of the clutch pedal, then tighten the lock nut; A warning After adjusting, tighten the bolt until it reaches the pedal stop, then tighten the lock nut. - rotate the pusher until the required free play is achieved, then tighten the lock nut. A warning When adjusting the mounting height or clutch pedal free play, be careful not to move the push rod towards the clutch master cylinder. 3. After completing the adjustments, check that the distance from the clutch pedal to the floor with the pedal depressed is correct. Free travel of the clutch pedal (A): 1-3 mm Distance from clutch pedal to floor with pedal depressed (B): 90 mm 4. If it is not possible to adjust the mounting height and free travel of the clutch pedal, there may be air in the hydraulic system of the clutch drive or the clutch master cylinder is faulty. In this case, bleed or disassemble and check the clutch master cylinder.

BLEEDING CLUTCH DRIVE HYDRAULIC

Any hydraulic system works normally if air is removed from it. A warning

When bleeding air, add only clean fluid recommended by the manufacturer.
The fluid used in the hydraulic drive will dissolve paint and plastic, so if the fluid gets on paintwork rinse the vehicle with plenty of water.

PERFORMANCE ORDER

1. Loosen the bleed nipple and connect a hose to it. Place the other end of the hose in a glass container of sufficient volume. 2. Slowly press the clutch pedal. 3. With the clutch pedal depressed, loosen the bleed nipple and bleed the air from the hydraulic system. Tighten the bleed union and release the clutch pedal. 4. Repeat operations until it comes out brake fluid without air bubbles. A warning Rapid repeated depressing of the clutch pedal in area B – C may cause the push rod to come out of the clutch cylinder housing during bleeding. It is necessary to press the clutch pedal only after its return to the upper position (A).

CLUTCH DRIVE AND PRESSURE DISCS

Clutch

PERFORMANCE ORDER

1. Drain the transmission oil and the brake fluid from hydraulic drive clutch. 2. Remove the transmission. 3. Install arbor 09411-11000 to center the clutch disc, which in this case will prevent the clutch disc from falling. 4. Gradually loosen the clutch assembly mounting bolts diagonally by turning each bolt by? turn until the diaphragm spring stops and the bolts can be loosened by hand. Remove the clutch cover with pressure plate and clutch disc. A warning Do not clean the clutch disc or clutch release bearing with solvent. It is advisable to remove the flywheel and check the rear o-ring crankshaft for leaks. Replace the O-ring if necessary.

Checking the clutch cover with a pressure plate

Checking the clutch disc

PERFORMANCE ORDER

1. Check the riveted connections of the friction linings to the clutch disc. Replace the clutch disc if defective. 2. Check the protrusion of the friction linings above the rivet heads. If the protrusion is less than the allowable, replace the clutch disc. Projection: 1.1mm 3. Check the condition of the clutch disc friction linings and, if there are traces of oil or mechanical damage, replace the clutch disc. 4. Clean the splines input shaft gearbox and install the clutch disc on the shaft. If the clutch disc moves along the shaft with difficulty or there is too much spline clearance, replace the clutch disc and / or input shaft.

Checking the clutch release bearing A warning

The clutch release bearing is sealed and must not be flushed.

PERFORMANCE ORDER

Checking the clutch fork

Installation

PERFORMANCE ORDER

1. Apply grease to the contact surfaces of the bearing, cylinder and clutch release fork. A warning When installing the clutch, apply grease to all moving joints of the parts, but do not use excessive grease as this may cause the clutch to slip. 2. Apply grease to the recess of the clutch release bearing. Lubrication: CASMOLY L9508 3. Apply grease to the contact surfaces of the release fork support. Lubrication: CASMOLY L9508 4. Use fine sandpaper to clean the flywheel and pressure plate surfaces and ensure that all abrasive material and grease are removed from the cleaned surfaces. 5. Lubricate the clutch disc splines and the transmission input shaft. Lubrication: CASMOLY L9508 6. Install the clutch disc and center it with the special tool 09411-11000. When installing the clutch disc, the marked surface of the disc must be on the side of the pressure disc. 7. Install the clutch cover with pressure plate onto the flywheel guide pins. 8. Gradually, in a diagonal sequence and in a specific order, tighten the flywheel mounting bolts. Tightening torque: 15-22Nm 9. Remove the clutch disc centering mandrel. 10. Install the transmission. 11. Adjust the clutch pedal free play.

Rice. 5.1. Clutch and its drive:

1 - clutch housing;

2 - clutch release fork;

3 - clutch release bearing;

4 - bolt of fastening of the clutch cover;

5 - clutch cover;

6 - a driven clutch disc;

7, 33 - pipelines;

8 - hose;

9 - lock plate;

10 - clutch release pedal bracket;

11 - bolt;

12 - axis of the clutch pedal;

13.14 - nuts;

15 - inner sleeve;

16 - returnable spring;

17 - outer pedal sleeve;

18 - clutch pedal;

19 - inner pedal sleeve;

20 - spring washer;

21 - pedal axis nut;

22 - washer;

23 - pusher axis;

24 - pusher;

25 - damper;

26 - retaining ring;

27 - piston;

28 - housing of the main cylinder of the clutch release hydraulic drive;

29 - clamp;

30 - clutch release hydraulic drive reservoir;

31 - cover;

32 - working cylinder of the clutch release hydraulic drive;

34 - valve for air removal;

35 - pusher.

Note:

This is how the clutch pedal adjusting unit looks like: 1 - bolt; 2 - pedal stop; 3 - nut

4.… loosen the lock nut on the pedal assembly with wrench 1 and turn the bolt with wrench 2 to achieve the required value of the full pedal travel.

A warning:

When adjusting the full pedal travel, make sure that the pusher does not move towards the clutch master cylinder.

5. To determine the free travel of the clutch pedal, measure the distance from the starting position of the pedal to the position at which an increase in resistance is felt when the pedal is pressed by hand. The nominal free travel of the clutch pedal is 6-13 mm. If the free play does not correspond to the nominal value, adjust the length of the pusher of the clutch master cylinder.

6. Holding flat 2 on the pusher of the clutch master cylinder with a wrench, loosen the lock nut 1 with a second wrench.

Note:

For clarity, the adjustment of the length of the pusher is shown in the removed master cylinder clutch release drive. It is not necessary to remove the master cylinder.

7. Rotating the pusher by the flat (shown by the arrow), adjust the free travel of the pedal (for clarity, the steering shaft is removed).

Note:

If the free travel of the clutch pedal is not correct, then it is possible that air has entered the clutch release hydraulic drive or the master cylinder is faulty.

8. Tighten the lock nut.

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General information

Tightening torques threaded connections, N m

Bolt of fastening the pedal to the bracket ..... 25-35

Bolt of fastening of the master cylinder to the pedal bracket ..... 17-26

Union nut for fastening the pipeline ..... 13-17

Pipe holder ..... 4–6

Bolt of fastening of the slave cylinder ..... 15-22

Hollow bolt of fastening of the pipeline to the working cylinder ... 25

Clutch cover retaining bolts ..... 15-22

Nut for fastening the pusher of the master cylinder to the pedal ..... 9-14

Ignition lock switch retaining nut ..... 8-10

Technical specifications

Clutch drive type	Hydraulic
Clutch disc	Dry, diaphragm
Outer / inner diameter of the driven disk, mm	215/145
Clutch cover assembly with pressure plate	With diaphragm pressure spring
Inner diameter: Working cylinder, mm Master cylinder, mm	20,64 15,57

Data for checks and adjustments

Clutch drive type	Hydraulic
Driven disc thickness (free) mm: Engines 1.3; 1.5 and 1.6 l Engine 1.1 l	8.5 ± 0.3 8.0 ± 0.3
Free travel of the clutch pedal, mm	6-13
Clutch pedal height above the floor, mm	160,7
Clutch pedal travel, mm
The gap between the working cylinder and the piston, mm	0,15
The gap between the main cylinder and the piston, mm	0,15

Applied lubricants

Place of application	Name
Contact surface of the fork with the clutch release bearing	CASMOLY L9508
Inner surface of the clutch release bearing	CASMOLY L9508
Mirror of the working cylinder, the outer surface of the piston and the cuff	Brake fluid DOT-3 or DOT-4
Clutch disc splines	CASMOLY L9508
Master cylinder mirror and piston outer surface	Brake fluid DOT-3 or DOT-4
Master cylinder pusher, pusher shaft and washer	Grease for wheel bearings SAE J310a, NLGI No.2
Clutch pedal axle and bushings	SAE J310a, chassis lubricant, NLGI-No.1
Contact surface of the clutch release fork with the pusher of the slave cylinder	CASMOLY L9508

Removal and installation of the clutch and its drive

The clutch and its drive are shown in rice. 3.1.

Removing air from the clutch hydraulic drive

Bleeding the clutch hydraulic drive should be carried out every time the connecting pipe, hose and / or master cylinder are removed, and also when the clutch pedal becomes "soft".

Loosen the tightening of the bleed nipple on the working cylinder ( rice. 3.2).

Slowly press the clutch pedal all the way down until the fluid stops flowing.

While holding down the pedal, tighten the bleed nipple.

Add the correct grade of fluid to the reservoir to the normal level.

Clutch master cylinder

The clutch master cylinder is shown in rice. 3.3.

Withdrawal

Drain working fluid through the pumping union.

Unscrew the master cylinder retaining nut ( rice. 3.4).

Disconnect the clutch hydraulic lines and hoses.

Remove the clamp fastening the pipeline to the gearbox ( rice. 3.5).

Check hose and piping for corrosion, pits and scoring.

Installation

Connect the pipeline to the slave cylinder.

Attach the flexible hose and secure it with the clamp ( rice. 3.6).

Install the master cylinder.

Attach the push rod to the clutch pedal.

Bleed the clutch actuator.

Disassembly

Remove the piston retaining ring.

Remove the pusher assembly with the piston, taking care not to damage the cylinder body and piston.

Check the cylinder mirror for corrosion, pits and scoring.

Check the cylinder liner for wear or misalignment.

Check the piston for corrosion, pits or scoring.

Check the cleanliness of the piping.

Check the inner diameter of the cylinder with a bore gauge and the outer diameter of the piston with a micrometer.

If the clearance between the piston and the cylinder exceeds the limit allowable size(0.15 mm), replace the master cylinder or piston.

Assembly

Apply DOT-3 or DOT-4 hydraulic fluid to the cylinder bore and outside of the piston.

Insert the piston into the cylinder.

Install the piston retaining ring.

Install the pusher.

Connect the hose to the cylinder body.

Clutch pedal

The clutch pedal and its mounting bracket are shown in rice. 3.7.

Withdrawal

Remove the cotter pin and washer ( rice. 3.8).

Remove the pedal mounting bolts ( rice. 3.9).

Checking the technical condition

Check the following:

- axle and pedal bushing for wear;

- the clutch pedal for bending and skewing;

- return spring for damage or weakening;

- pedal pad for damage or wear;

- the height of the pedal above the floor A (from the outer surface of the pedal pad to the floor) ( rice. 3.10 ). It should be 160.7 mm.

If the height of the pedal above the floor is not correct, adjust it as follows.

1. Adjust the pedal height with the bolt, and then tighten the lock nut.

2. By rotating the pusher, adjust its length to the new pedal height ( rice. 3.11 ), then secure the pusher with a nut.

After completing the adjustment, check that the clutch pedal free travel (measured from the surface of the pedal pad) is within 6-13 mm ( rice. 3.12).

If the free travel of the clutch pedal is not correct, it means that air has entered the hydraulic drive or the master cylinder is faulty. Bleed the hydraulic actuator and check the master cylinder or clutch.

Checking the ignition lock switch. Check the integrity of the electrical circuit between the contacts of the switch ( rice. 3.13).

Installation

Apply multi-purpose grease at the locations indicated by the arrows on the rice. 3.14.

Install the nuts ( rice. 3.9).

Install the clutch pedal shaft cotter pin.

Clutch cover and driven disc

Clutch cover and clutch disc shown in rice. 3.15.

Withdrawal

Drain clutch fluid and transmission oil.

Remove the transmission (see subsection "Transmission").

Insert arbor 09411-25000 into the hole in the driven disc hub to prevent it from falling.

Loosen the clutch cover bolts to the flywheel crosswise.

Loosen the bolts alternately, one to two turns each time, to prevent the casing flange from warping ( rice. 3.16).

Checking the technical condition

Clutch cover.Check the ends of the diaphragm spring petals for wear and height differences.

Check the pressure plate surface for wear, cracks and discoloration.

Check for loose rivets and replace clutch cover if necessary.

Driven disc. Check the friction linings for loose rivets, uneven seating, sticking damage, oil or grease adhesion. Replace the damaged clutch disc if necessary.

Check the thickness of the driven disc in a free state ( rice. 3.17).

Check the disc springs for play and damage, replace the faulty disc if necessary.

Clean the splines on the transmission input shaft and install the driven disc.

If the disc is difficult to move along the splines of the shaft or there is excessive clearance, replace the driven disc and / or the input shaft of the gearbox.

Clutch release bearing.Check the clutch release bearing for binding, damage, or excessive noise. Check the contact points of the diaphragm spring with the bearing race for wear.

Replace the bearing if the contact points with the clutch release fork are heavily worn.

Clutch release fork.Replace the clutch release fork if it is heavily worn at the points of contact with the clutch release bearing.

Installation

Apply multi-purpose grease to the clutch release fork where it contacts the clutch release bearing and slave cylinder.

Apply grease (see. rice. 3.18).

Apply multi-purpose grease to the groove of the clutch release bearing.

Apply CASMOLY L9508 multipurpose grease to the clutch release fork where it contacts the clutch release lever shaft.

Thoroughly clean the surfaces of the flywheel and pressure plate with a fine grit cloth and make sure they are free of oil or grease.

Apply a small amount of CASMOLY L9508 multipurpose grease to the splines of the driven disc hub and transmission input shaft.

Using the tool 09411-25000, install the clutch plate on the flywheel with the factory marking towards the pressure plate.

Install the clutch cover on the flywheel and install the six mounting bolts.

Tighten the bolts crosswise to a torque of 15-22 Nm. Tighten the bolts alternately, one to two turns each time, to prevent buckling of the clutch housing flange.

Remove the driven disc centering mandrel.

Install the transmission (see subsection "Transmission").

Adjust the clutch pedal free play.

Clutch slave cylinder

Withdrawal

Disconnect the connecting line from the slave cylinder.

Remove the slave cylinder mounting bolt ( rice. 3.20).

Checking the technical condition

Check the slave cylinder for traces of fluid leaks.

Check the slave cylinder cover for damage.

Disassembly

Disconnect the connecting hose from the cylinder, remove the valve plate, spring, pusher and cover.

Carefully remove any dirt around the piston bore of the slave cylinder.

Remove the piston from the cylinder with a jet of compressed air directed into the cylinder ( rice. 3.20).

Increase the air pressure gradually to prevent brake fluid from spilling out into the eyes or on the skin.

Checking the technical condition

Check the slave cylinder mirror for corrosion or damage.

Using a bore gauge, check the inside diameter of the cylinder at three locations (bottom, middle and top). If the clearance between the piston and the cylinder exceeds the maximum permissible, replace the slave cylinder.

Extremely allowable clearance 0.15 mm between piston and cylinder.

Assembly

Apply the correct grade of brake fluid to the inner surface of the slave cylinder and the outer surface of the piston and the piston cup, and install the piston into the cylinder.

Used fluid: brake fluid DOT-3 or DOT-4.

Installation

Install the valve plate, tappet and boot.

Lubricate the pusher shaft with CASMOLY L9508.

Install the clutch slave cylinder and connect the pipeline to it.

Install the slave cylinder mounting bolts ( rice. 3.21).

Useful information and advice

Causes of clutch slipping or incomplete disengagement when pressing the pedal

Slipping of the clutch is manifested in the fact that with a completely serviceable engine, the car does not climb slopes well, accelerates slowly. This can be caused by oily or severe wear of the discs, reduced spring elasticity, lack of free travel of the clutch pedal.

Incomplete disengagement of the clutch causes difficulty and noise when shifting gears and can lead to premature failure of the synchronizers and accelerated wear of the gearbox teeth. This malfunction most often occurs when dirty, skewed or deformed discs, incorrect adjustment of the position of the release levers, too much free travel of the clutch pedal.

It should be borne in mind that transmission noise is not always the result of incomplete clutch disengagement. Noise can be generated by wear or misalignment of bearings, wear or improper meshing of bevel gears. A strong knock in the indicated places indicates a serious malfunction that requires an immediate stop of the vehicle and repair of the unit.

Causes of difficult gear shifting or spontaneous shutdown

Difficulty shifting gears or their spontaneous shutdown is the result of wear of the locks and latches or the drive of the gearshift mechanism. Here you cannot do without serious repairs.

Such malfunctions can be prevented in the following ways: periodically carefully check the reliability of fastening of all units and parts of the power train, monitor the oil level in the gearbox and change it in a timely manner.

Clutch elements: 1 - clutch housing; 2 - clutch release bearing; 3 - clutch release fork; 4 - clutch slave cylinder; 5 - clutch cover; 6 - pressure plate; 7 - flywheel; 8 - driven disk with a spring damper of torsional vibrations

General information

Technical specifications

Dry, diaphragm

Outer / inner diameter of the driven disk, mm

20,64

15,57

0,15

Place of application
	CASMOLY L9508

General information

Clutch Hyundai getz located between the engine and the gearbox and is designed to disconnect and connect the flywheel located on the engine crankshaft and the input shaft of the gearbox.

The clutch consists of a driven (friction) disc, a clutch cover with a pressure plate and a diaphragm spring, and a clutch release mechanism. The friction disc consists of two annular friction linings that are attached to the hub via damper springs.

A diaphragm spring mechanism creates a force that combines the work of the flywheel, pressure and driven discs to rotate together, in which case the clutch engages and transfers torque from the engine to the gearbox. The clutch is controlled by the clutch pedal.

The clutch is disengaged as follows. As a result of pressing the clutch pedal, the piston moves in the master cylinder, compressing the fluid, the pressure of which is transmitted through the hose to the clutch slave cylinder, the piston of which, in turn, acts on the clutch release fork. The clutch release fork moves the clutch release bearing, which presses on the center of the diaphragm spring, thus releasing the closing force around the spring and moves the pressure plate back. This releases the driven disc, after which the motor shaft and the gearbox shaft can rotate independently of each other.

Friction linings are fixed on both sides of the driven disc. The leading part of the disk is connected to the hub through the parts of the torsional vibration damper, which provides an elastic connection between them. The vibration damper reduces dynamic loads that cause twisting (untwisting) of the transmission shafts, which occur when the vehicle speed changes sharply, hitting road irregularities, when the clutch is suddenly engaged, and also due to uneven engine torque. Elastic vibrations of transmission parts lead to the appearance of noise in mechanisms and assemblies, as well as vibrations, as a result of which damage to parts is possible if the amplitude of elastic vibrations reaches significant values. A damper serves to absorb the energy of elastic torsional vibrations.