User Guide

EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
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EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
3
From
DAIKIN to
EXEDY
Our company pursues
excellence in every
aspect of our operations.
To better express this
attitude, in August
1995 we changed our
name from Daikin
Manufacturing Co., Ltd.
to EXEDY Corporation.
The new name was
coined by combining
“Excellence” and
Dynamic” — terms that
describe our qualities
as a corporation. At the
same time we adopted
a new corporate logo,
composed of three
curved lines that form
an ‘X’, representing
society, customers and
employees. The colors
used in the corporate
logo - known as “excellent
blue” and “dynamic
red” - now serve as our
corporate colors.
Industry Standard
Leaders in
drivetrain
technology
As a leading manufacturer
of drivetrain components,
EXEDY Corporation is
committed to providing
superior products,
technology and services.
We bring decades of
experience and a wealth
of know-how to our eorts
to develop products that
meet the needs of today’s
industries.
Already at the top of
our eld, EXEDY is now
moving forward toward
new challenges in the
21st century.
EXEDY’s product lines range from clutches for cars, industrial
machinery and construction machinery to torque converters
and transmissions. Each product is manufactured under a
system that integrates all processes from development to
assembly and inspection, assuring the reliable products
our customers have come to expect. Advanced, exible
production systems do more than meet customer
requirements in quality, cost and delivery time. It also
results in products that oer the high levels of comfort and
operability today’s competitive market demands.
Contents
The Fault The Fix
Dicult disengagement
Check hydraulics before
replacing the clutch
Slipping clutch
Check thrust bearing for free travel
before replacing the clutch
DO NOT ASSUME ON ANY CLUTCH REPLACEMENT
Getting it right the rst time ...
EXEDY Corporate Prole ................................................................................. 4
EXEDY Worldwide Network ........................................................................... 5
Cautions for Handling & Installation Preparation .................................. 6
Function of a Manual Clutch ......................................................................... 9
Function of a Twin Plate Manual Clutch ..................................................13
How to Get it Right the First Time .............................................................14
Check Before Replacing ................................................................................15
Malfunctions of Clutch Discs ....................................................................... 24
Malfunctions of Clutch Pressure Plate Cover Assemblies .................34
Malfunctions of Other Clutch Components ..........................................45
Diagnosing Bearing Noises ..........................................................................51
Malfunctions of Sports/Performance Clutches ....................................52
Choosing the Correct Sports/Performance Clutch .............................56
Function of Various Sports/Performance Products .............................58
How to Identify Your Clutch .........................................................................66
Features of EXEDY Unity Type Dampener ..............................................67
Driveline Misalignment .................................................................................68
Pull-Type Clutch Design Technology ........................................................69
Torque Specications for Flywheel & Pressure Plate ..........................70
Hydraulic Clutch Pedal Adjustments ........................................................71
Please Read Before Installation ..................................................................72
Beware of Imitations/Inferior Products ...................................................73
Metric & Imperial Measurement Conversion Table .............................74
With any clutch problem it is vital to diagnose the cause of clutch
malfunction. Here are two examples in which merely replacing the
clutch would not have xed the fault.
For example...
How to Use this Guide
Clutches transmit power for gear shifting and stopping.
The essential qualities of a clutch are:
• Sure disengagement
• Smooth engagement
• Ecient gear change
• Performance and durability
• Absorption of noise and vibration from the engine
and power train.
Clutch eciency depends on the make of car, the clutch
usage, as well as maintenance of the clutch. You must choose
and t the appropriate clutch to the vehicle and know how
to install, use and operate the clutch correctly. Many clutch
complaints and problems are caused by factors other than the
clutch component itself — incorrect usage, faulty tting and
poor maintenance can all contribute to the fault. This manual
shows a wide range of clutch problems which can occur and
lists the reasons for the problem. EXEDY has been supplying
and servicing clutches in the market place for many years with
advanced technological know-how and much experience gained
from supplying the Original Equipment market. We are sure you
will appreciate both our service and our Fault Finding Guide
tting, operating and maintaining your clutch.