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With clutch replacement being an involved and time- consuming operation, Rob Marshall looks at how quality suppliers help you get it right, first time.
With the modern manual transmission clutch looking much the same as it has for the last half-century, do not presume that it has not changed. As the years have rolled by, clutches have had to tolerate increased engine torque, higher vehicle weight, lighter construction and more environmentally friendly friction materials. Further developments have included the need for the clutch pedal weight not only to be minimised but also to remain relatively unchanged throughout the clutch's life, hence the self-adjusting cover/pressure plate.
Even so, some things have remained the same. While there have been some exceptions, clutch replacement for most cars is heavy and laborious work. Yet, modern cars make the task more complex. Not only are more parts in the way but also subframes, or even steering racks, might need dismounting. Therefore, you risk damaging components, especially the replacement clutch, by working in less- than-ideal situations.
One might also think that, with electrification and declining sales of manual H-pattern gearboxes, aftermarket dry-clutch work is dying. From speaking to a Midlands-based clutch replacement specialist, we were assured that this is not the case. One reason for this is the sheer number of double-clutch (2CT) gearboxes (not just from the Volkswagen Group) that are equipped with dry clutch packs.
Therefore, with clutch work buoyant, traditional clutches requiring new techniques and 2CTs offering fresh opportunities, there has never been a more opportune time for technicians to take advantage of the extra support that is available from quality clutch producers.
Help at hand...
Few of us would disagree with Valeo’s stance that avoiding assembly errors and ensuring a professional fit are paramount. Through the Tech Assist platform, Valeo assists technicians by providing free access to resources, including a ‘Tutorials’ section. This features diagnostic assistance and detailed fitting videos with tips that streamline the clutch replacement process. The ‘Documents’ section offers immediate access to Technical Bulletins and comprehensive fitting guides. For ease and speed of access, information is indexed and available instantly when a technician enters the specific Valeo reference number. In addition, Tech Assist includes integrated technical data and torque specifications.
Blue Print includes printed instructions on how to prepare and fit the new clutch kit in every box, with supplementary guidance, where necessary, such as on concentric slave cylinder manual bleeding procedures. This information is replicated within
the bilstein group’s partsfinder, which also features digital links to any relevant Clutch Clinic articles, or installation videos. An example of a typical support video is for its clutch part number ADB113017, demonstrating a Clutch Clinic installation for a BMW 1-Series. Notably, it includes a dedicated bulletin outlining the required release-bearing clearance for these BMWs, detailed in Technical Bulletin 1 and Technical Bulletin 2.
Special tools are also becoming fundamental to a successful clutch change and aftermarket providers are recognising this. For instance, Blue Print supplies a clutch removal and replacement tool kit for its self-adjusting clutch, which it emphasises as essential because it locks the adjusting ring in place during installation.
However, all of this is pointless if you select the wrong part. Blue Print highlights the bilstein group partsfinder site, a comprehensive catalogue that is shared with the firm’s febi brand. It identifies parts based on free text, OE and competitor references, engine codes and registration plate numbers. While most of Blue Print’s clutches are supplied as complete kits, with all required components included, you can still find a full breakdown of the individual components on the parts page. Should you get stuck, the firm highlights its UK support team, which is available via e-mail (technical.sales@bilsteingroup.com) or telephone 01246 479080.
Valeo’s Tech Assist also boasts a powerful search facility, by vehicle details, original equipment (OE) part numbers, or Valeo references. For more complex identification needs, its Help Centre offers email, live chat, and phone support, should you struggle with cross-referencing and finding the correct part. Valeo also highlights its more specialist resources, such as the FullPackTM DMF Finder. Designed for passenger cars, it also allows you to input OE numbers for the DMF, clutch, or slave cylinder/release bearing/CSC and find the corresponding Valeo FullPack kit reference immediately. The Truck Clutch Kit finder supports commercial vehicles in a similar way, by identifying the correct Valeo clutch kit from individual clutch plate, disc, and release bearing part numbers. Valeo reminds us that its customer support facility is integrated within Tech Assist.
Clutch Groupies...
Traditionally, clutches have been supplied in three pieces, comprising release bearing, drive plate and pressure plate/cover. Today, clutch developments have challenged this convention, making the ordering and installation process more complex. Valeo has strived to simplify this, by grouping essential components into a single kit of multiple parts. Take the DMF FullPack kit as an example, which brings the Dual Mass Flywheel, clutch and slave cylinder/release bearing together within a single box. Another example is the Dual Dry Clutch kit for Kia and Hyundai applications, which includes the clutch pack, release forks and release bearings required for the repair.
Blue Print also supplies various kits, comprising two, three, or four components, where required. This latter option includes a four-piece clutch kit, with the DMF, CSC and fixing bolts. However, it also highlights its ‘Smartfit Kit’ as a reliable, easy to install aftermarket conversion for OE self-adjusting clutches. For more information, see this link.
Schaeffler has also grouped parts together to make your life easier. Its LuK RepSets comprise RepSet (a traditional two, or three, piece kit), RepSet Pro (three-piece including CSC), RepSet DMF, RepSet 2CT and the new RepSet 2CT DMF, which includes a double clutch pack and flywheel.
So, whether you are tackling a traditional clutch, or the more complex 2CT dry replacements, be aware that you are
not on your own. With the right training, accurate parts identification and on- the-job backup, you can be confident that the quality aftermarket suppliers have your back.
Training...
Clutch training is still highly worthwhile. Valeo’s Tech Academy offers both online and in-person training. All of these IMI-accredited sessions (which are not limited to clutches alone) can be booked via the Tech Academy website: www.valeoservice.co.uk/en-uk/tech-academy
You can access Schaeffler’s IMI-certified training through your 1TEC, AutoCare and SERVICESURE memberships. Sessions comprise a two-day course covering a range of wet & dry double clutch systems, which includes both theoretical and practical demonstrations, as well as a hands-on assessment. Schaeffler also hosts a small number of double-clutch training events at various sites throughout the year for workshops that do not have access through a garage programme. Keep your eyes peeled for information on teaser training sessions, delivered at dozens of trade shows and technical evenings across the country.
LuK’s REPXPERT...
Schaeffler’s Vehicle Lifetime Solutions makes much of its capitalised lettered digital portal. Designed for use across all of the firm's brands, including INA, FAG and Vitesco, this comprehensive service portal is proving its worth for technicians.
To help you or your office colleagues locate the correct clutch, a VRN catalogue is embedded within the app. Should you still struggle, you can contact a dedicated technical team through the Repxpert hotline. To keep you updated on product enhancements, InFocus bulletins are also available through Repxpert.
Dedicated Repxpert tools are also available to help you with correct installation. These include a DMF implement for tolerance checking and to aid both diagnosis and replacement. The Self-Adjusting Clutch tool helps to align any clutch during fitment and helps avoid the most common installation misalignment problem. Repxpert 2CT tools are also available for a range of double-clutch transmission systems, including Volkswagen Group’s wet or dry DSG transmissions.
A feature that has proven particularly popular amongst technicians (as proven at this year’s Repxpert conference) is its loyalty scheme. This comprises a ‘Bonus Shop’ that is accessible within the app, so members can exchange their accrued points for not only Repxpert special tools and clothing but also DeWalt and Laser-branded tools. Schaeffler continues to expand its Bonus ranges, including customisable workshop clothing and technician essentials such as kettles, toasters and coffee machines.
While it is commendable and sensible to have all of these features grouped together in one place, the effort is wasted, should the system be convoluted and restrictive to use. Fortunately, Schaeffler has thought of this. After installing the Repxpert app, you can scan the OneCode that features on every LuK box, or, indeed, every Schaeffler product label.
Scanning the code confirms part compatibility and provides a quick link to product information, technical updates, and even fitting guides. Powered by TecRMI, you will discover vehicle manufacturer installation instructions and labour times, torque figures and other relevant specifications. Furthermore, with so many counterfeit products circulating, it also confirms the part’s authenticity for your peace of mind.
You can also accrue the aforementioned bonus points, by scanning the OneCode. Once done, click on the ‘collect points’ button and the software does the work.
