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Cos Modul 7 Clutch Repair

This module provides training on clutch system repair over 14 steps. Trainees will learn to identify clutch system components, service gear shift linkages, change clutch cables, service the clutch master pump and slave cylinder, bleed the hydraulic clutch system, remove and repair the transmission and clutch assembly, and reinstall components. The module aims to develop skills in clutch system repair using various tools and following manufacturer specifications. Assessment involves practical tests of skills and written or oral tests of knowledge.

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eizz88
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© © All Rights Reserved
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Download as DOC, PDF, TXT or read online on Scribd
105 views

Cos Modul 7 Clutch Repair

This module provides training on clutch system repair over 14 steps. Trainees will learn to identify clutch system components, service gear shift linkages, change clutch cables, service the clutch master pump and slave cylinder, bleed the hydraulic clutch system, remove and repair the transmission and clutch assembly, and reinstall components. The module aims to develop skills in clutch system repair using various tools and following manufacturer specifications. Assessment involves practical tests of skills and written or oral tests of knowledge.

Uploaded by

eizz88
Copyright
© © All Rights Reserved
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
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COURSE OF STUDY

AUTOMOTIVE TECHNICIAN (P-119-1)


MODULE 07: CLUTCH SYSTEM REPAIR
Module Synopsis:
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

Module Objectives:
Carry out clutch system repair using service manual, hand tools set, replacement parts, PPE, steel ruler, bleeding equipment, lubricant and
fluid, special tools, measuring tools and transmission support so that clutch system component location identified, gear shift linkage removed,
gear shift linkage examined, gear shift linkage installed, clutch cable removed, clutch cable changed, clutch master pump and clutch slave
cylinder serviced, hydraulic clutch system bleeding conducted, transmission from vehicle and clutch assembly removed, clutch assembly
examine, clutch assembly assembled and transmission to vehicle installed in accordance with manufacturers specification.

Module Content
Task No
06.07 Service gear shift linkages
06.01 Replace vehicle clutch cable
06.02 Rectify hydraulic clutch system
06.03 Rectify vehicle clutch assembly

63

STEPS
1.

Identify clutch
system component
location

KNOWLEDGE

PERFORMANCE

1.1 Purpose of clutch system


1.2 Layout of clutch system
component
1.3 Function and operation of
clutch system

HRS
2

1.1 Locate clutch system


1.1 Inspect functionality of
clutch system
Mechanical system
Hydraulic system

DELIVERY
MODE
Lecture

Demonstration and
Observation

Lecture

Attitude/Safety
Wear PPE

2. Remove gear shift


linkage

2.1 Layout of gear shift


linkages
2.2 Types of gear shifting
linkages
Rod
Cable
2.3 Procedures of removing
gear shift linkage

64

ASSESSMENT MODE
1. Knowledge (D)
2. Performance (A & C)
Locate clutch system
Inspect functionality
of clutch system
- Mechanical
system
- Hydraulic system
Inspect functionality
gear shifting linkage
Detach gear shift
Linkages
Inspect condition of
gear shift linkages
- Bent
- Stuck
- Damage
Fix gear shift linkages
Adjust gear linkages
Detach clutch
cable
Inspect condition of
clutch cable
- Bent
- Stuck
- Damage
Fix clutch cable

STEPS

KNOWLEDGE

PERFORMANCE

HRS

2.1 Determine gear shifting


Linkage location
Rod
Cable
2.2 Inspect functionality
gear shifting linkage
2.3 Detach gear shift
linkages

Attitude/Safety
Use fender cover for
safety

65

DELIVERY
MODE
Demonstration and
Observation

ASSESSMENT MODE

Adjust clutch pedal


free Play
Remove clutch
master pump
Dismantle clutch
master pump
Inspect clutch
master pump
components
Assemble clutch
master pump
components
Refit clutch master
pump

STEPS
3. Examine gear shift
linkage

KNOWLEDGE

PERFORMANCE

3.1 Function of gear shift


linkage
3.2 Procedures of checking
gearshift linkage condition

HRS
1

DELIVERY
MODE
Lecture

3.1 Inspect condition of gear


shift linkages
Bent
Stuck
Damage

Demonstration and
Observation

4.1 Procedures of fixing gear


shift linkages
4.2 Techniques of adjusting
gear shift linkages

Attitude/Safety
Meticulous when
checking gear linkage

4. Install gear shift


linkage

ASSESSMENT MODE

Lecture

4.1 Fix gear shift linkages


4.2 Adjust gear linkages
Attitude/Safety
Grease moving joint for
safety

66

Demonstration and
Observation

Remove clutch slave


cylinder
Dismantle clutch
slave cylinder
Inspect clutch slave
cylinder components
Assemble clutch
slave cylinder
components
Fix clutch slave
cylinder
Bleed hydraulic clutch
system
Test clutch for proper
function
Detach transmission
assembly
Describe construction
clutch components
Dismantle clutch
Assembly
Inspect friction disc
- Facing wear
- Run out
- Damage
Inspect pressure
plate

STEPS
5. Remove clutch
cable

KNOWLEDGE

PERFORMANCE

5.1 Function of clutch cable


5.2 Techniques of removing
clutch cable
5.1 Detach clutch cable
5.2 Inspect condition of
clutch cable
Bent
Stuck
Damage

HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE

Attitude/Safety
Meticulous when checking
clutch cable

6. Install clutch
cable

6.1 Procedures of installing


clutch cable
6.2 Purpose of pedal free play
6.1 Fix clutch cable
6.2 Adjust clutch pedal free
play
Attitude/Safety
Meticulous when
installing clutch cable

67

Lecture

Demonstration and
Observation

- Wear
- Scoring
- Warping
- Damage
Inspect clutch release
bearing condition
- Noise
- Damage
Measure flywheel
surface run out
Inspect pilot bearing
condition
- Noise
- Damage
Fix clutch assembly
Adjust clutch free
play
Attach transmission
to vehicle

STEPS
7. Service clutch
master pump

KNOWLEDGE

PERFORMANCE

7.1 Function and operation of


clutch master pump
7.2 Construction of clutch
master pump
7.3 Procedure of servicing
clutch master pump
7.1 Remove clutch master
Pump
7.2 Dismantle clutch master
Pump
7.3 Clean and inspect clutch
master pump
components
Wear and tear
Scratch
7.4 Assemble clutch master
pump components
7.5 Refit clutch master
pump
Attitude/Safety
Meticulous in servicing
clutch master pump

68

HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE

STEPS
8. Service clutch
slave cylinder

KNOWLEDGE

PERFORMANCE

8.1 Function and operation of


clutch slave cylinder
8.2 Construction on clutch
slave cylinder
8.3 Procedures of servicing
clutch slave cylinder
8.1 Detach clutch slave
cylinder
8.2 Dismantle clutch slave
cylinder
8.3 Clean and inspect clutch
slave cylinder
components
Wear and tear
Scratch
8.4 Assemble clutch slave
cylinder components
8.5 Fix clutch slave cylinder
Attitude/Safety
Meticulous in servicing
clutch master pump

69

HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

ASSESSMENT MODE

STEPS
9. Conduct hydraulic
clutch system
bleeding

KNOWLEDGE

PERFORMANCE

9.1 Types of clutch fluid


9.2 Hydraulic clutch system
bleeding procedure
9.1 Bleed hydraulic clutch
system
9.2 Use bleeding tools
9.3 Test clutch for proper
function

HRS

DELIVERY
MODE

Lecture

Demonstration and
Observation

Lecture

Demonstration and
Observation

Lecture

Attitude/Safety
Meticulous in bleeding
air from clutch system
10. Remove
transmission from
vehicle

10.1Types of transmission
Gear box Transmission
Transaxle
10.2 Location of transmission
10.3 Procedures of removing
transmission assembly

10.1 Detach transmission


assembly
Attitude/Safety
Meticulous in handling
heavy component

11. Remove clutch


assembly

11.1 Types and function of


clutch system
11.2 Construction and
operation of clutch system
11.3 Procedures to dismantle
clutch assembly

70

ASSESSMENT MODE

STEPS

KNOWLEDGE

PERFORMANCE
11.1 Detach clutch
assembly
11.2 Dismantle clutch
assembly

HRS

DELIVERY
MODE

Demonstration and
Observation

Lecture

Demonstration and
Observation

Attitude/Safety
Avoid scratching clutch
pressure plate
12. Examine clutch
assembly

12.1 Types and function of


clutch disc
12.2 Construction and
operation of clutch disc
12.3 Types and function of
pressure plate assembly
Single plate dry clutch
Diaphragm spring
12.4 Construction and
operation of pressure
plate
12.5 Types and function of
clutch release bearing

12.1 Inspect friction disc


Facing wear
Run out
Damage
12.2 Inspect pressure plate
Wear
Scoring
Warping
Damage

71

ASSESSMENT MODE

STEPS

KNOWLEDGE

PERFORMANCE

HRS

DELIVERY
MODE

12.3 Inspect clutch release


bearing condition
12.4 Measure flywheel
surface run out
12.5 Inspect pilot bearing
Condition
Attitude/Safety
Meticulous when
measure components
13. Assemble clutch
assembly

13.1 Procedures of fixing clutch


assembly
13.1 Fix clutch assembly
13.2 Adjust clutch free play

Lecture

Demonstration and
Observation

Lecture

Demonstration and
Observation

Attitude/Safety
Meticulous in fixing
clutch assembly
14. Install
transmission
to vehicle

14.1 Procedures of installing


transmission to vehicle
14.1Attach transmission to
vehicle
Attitude/Safety
Use vacuum cleaner for
fibers dust

72

ASSESSMENT MODE

STEPS

KNOWLEDGE

PERFORMANCE

HRS

DELIVERY
MODE

ASSESSMENT MODE

Core Abilities
01.04 Analyze Information
01.05 Utilize the internet to locate and gather information
03.08 Develop and maintain c cooperation within work group
04.01 Organize own work activities
04.02 Set and revise own objectives and goals
04.03 Organize and maintain own workplace
04.04 Apply problem solving strategies
04.05 Demonstrate initiative and flexibility

NOTE ON ASSESSMENT MODE:


A : Practical; B : Project; C : Oral; D : Written; E : Others

73

Selected References and Audio Visual Materials


REFERENCES
1.

Anthony E.Schwaller (2004) Total Automotive Technology, 4th


Edition-Delmar Learning, New York USA, ISBN: 1-4018-2476-5

2.

Ed May (2003) Automotive Mechanic Vol 2 7th Edition, Mc GrawHill Australia ISBN: 0074712969

AUDIO VISUAL MATERIALS

Tools, Equipment Supplies and Facilities


ITEMS
1. Service manual
2. Hand tools set
3. Lubricant/grease
4. Replacement parts
5. Wheel stopper
6. Personal protection equipment
7. Fender cover
8. Steel ruler
9. Bleeding equipment
10. Lubricant and fluid
11. Special tools
12. Measuring tools
13. Transmission support

RATIO (Equipment : Trainees)


1:5
1:5
As per required
As per required
As per required
1:1
1:5
1:5
As per required
1:5
1:1
1:5
1:5

74

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