Valeoscope Commercial Vehicles Clutch 2020

Diagnosis Hard gear shifting

3.1.4 Gearbox with synchromesh

Advice  ą ą Make sure that the engine and the gearbox are well sealed. Remove grease on friction surfaces (flywheel, pressure plate), input shaft splines, tube-guide and clutch surroundings (housing…). ą ą If the gearbox input shaft splines and the release bearing sleeve must be greased, use an appropriate quantity of good quality grease. ą ą Makesure that the facings arenot contaminated with grease during their installation. 14. Disconnected pre-damper Clutch inspection ●● Pre-damper is disconnected with damaged splines. ●● The hub is disconnected on flywheel side; the damaged splines are on the gearbox side. Vehicle behavior ●● Noise in clutch ●● Wrong declutching ●● Vehicle stopped

Advice  ą ą Use appropriate tools (gearbox cradle instead of hoist, centring guide…). ą ą Carefully install the gearbox (orientation, alignment and introduction). 

Clutch inspection Burst of the clutch disc Vehicle behavior ●● Slippage or sudden stop of vehicle ●● Clutch noise Reasons

15. Retainer plates are broken Clutch inspection ●● Friction marks on the damper system ●● Retainer plates are deformed or broken Vehicle behavior ●● Noise in clutch ●● Wrong clutch release ●● Vehicle stopped

1. The switch is in position of LOW RANGE "LR": ●● Start in 1 st gear (or crawler "C" if necessary). ●● Sequential shifting on 2 nd , 3 rd , 4 th gear and 5 th gear. 2. The switch is pushed in position HIGH RANGE "HR": ●● Sequential shifting on 5 th , 6 th , 7 th and 8 th gear. (Ex: 1 st , 2 nd , 3 rd and 4 th gear). ● ● If one forgets to move the switch when on 4 th gear, instead of up-shift from 4 th  5 th , a down-shift from 4 th  1st is done. When a down-shift from 4 th  1 st is done, the gearbox input shaft can reach a rotating speed of more than 7.000 rpm (depends on gear ratios). Clutch inspection Burst on the clutch disc Vehicle behavior ●● Slippage or sudden stop of vehicle ●● Clutch noise Reasons 1. The switch is in position of LOW RANGE "LR": ●● Start in 1 st gear (or crawler "C" if necessary). ●● Sequential shifting on 2 nd , 3 rd , 4 th gear and 5 th gear. 2. The switch is pushed in position HIGH RANGE "HR": ●● Sequential shifting on 6 th , 7 th , 8 th , 9 th and 10 th gear. (Ex: 1 st , 2 nd , 3 rd , 4 th and 5 th gear). ● ● If one forgets to move the switch when on 5 th gear, instead of up-shift from 5th  6 th , a down-shift from 5 th  1 st is done. Diagnosis There should be some mistakes in the gearbox usage during up shifting, when the switch "LR" to "HR" is forgotten.

H type with range switch on shift lever

Retainer plates are broken

Reasons ●● Mistake of mounting direction of the clutch disc. ●● Wrong part number, wrong disc. Diagnosis ò ò The damper is fitted incorrectly (on flywheel side instead of gearbox side). ò ò The clutch disc thickness is not compatible (with flywheel or cover assembly). ò ò The damper is disconnected from the facings (clutch disc and retainer plates broken) Attention Ɂ Ɂ Avoid mounting the clutch disc upside down. In general the longest part of hub is on the cover assembly side (also marked gearbox side). Advice   Replace the seals of the crankshaft on the engine side and of the primary shaft on the gearbox side to eliminate oil leaks.

Disconnected pre-damper

Reasons ●● Shock on the hub due to the rocking of the gearbox when it is fitted back on the engine with a hoist. ●● During the assembly of the gearbox, the input shaft was pushed strongly against the clutch disc hub. Diagnosis ò ò During the assembly, the gearbox hit strongly the disc hub. ò ò Wrong centring of the clutch disc. Attention Ɂ Ɂ Use a centring tool to center the clutch disc properly, and avoid mis-alignment of the gearbox shaft.

sH type with range switch on shift lever by contactor

34

35