INTRODUCTION

Welcome to the course Automotive!

This course is an introduction to Power Train and Under Chassis

Servicing, Preparing and Maintenance program development as well as its
management and awareness. It provides the materials needed for basic
understanding of the operation of Power Train and Under Chassis Servicing,
Preparing and Maintenance.

The main objective of this program is to prepare the students in handling,

maintaining and repairing the automobile Power Train and Under Chassis
through safe and healthful conditions for the prevention of loss or damage to
lives and properties as their future careers.

The content of this module was taken from different and liable resources
based on guidelines of the course requirement. Assuredly, this module will help
students in learning the basic operations of this course. Through the content of
this, learners’ skills will be developed and enhanced because this module was
written to be used as an applied thermo science in college or undergraduate
courses on Power Train and Under Chassis.

And it also helps for the complete development and enhancement of every
learner as they prepare their selves as automotive technicians.

Grading System (BTVTE- Automotive)

Module/Portfolio/Activities 50%

Laboratory 30%

Exam 20%

Enjoy learning!
Lesson 1

Learning Objectives:
a. Discuss the main role of Power Train and Under Chassis.
b. Describe Power Train and Under Chassis.
c. draw and label power drive train.

Power Train and Under Chassis

Drive Train

Engine is the source of power in an automobile. The fuel burned inside the
combustion chamber produces high pressure which forces the piston to
move up in down in the cylinder. This movement is carried mechanically
by the connecting rod and causes the crankshaft to rotate. This rotary
motion is carried to the car wheels thus enabling the wheels to move the
rotate.

The power developed to the engine passes through a series of

mechanism before reaching the wheel. This mechanism is the drive or
power train and is composed of clutch, transmission, and propeller shaft,
universal joints, differential and rear axles. This is the common system
arrangement. Modern cars which are front drive differ in the arrangement
as the engine system are coupled directly to the clutch, transmission,
differential, and axle.

Fig 1 show the conventional arrangement of drive trains where the engine
is mounted longitudinally while Figure 2 shows the engine mounted
transversely and driving the front wheels.

Fig. 1. The drive train unit

In addition to front-wheel and rear-wheel, drive some vehicle of various brands
have four-wheel drive or all-wheel drive. Automotive vehicles equipped with car-
wheel drive engines used transmission front-wheel drive and all-wheel drive
engines used transaxle.

All wheel drive means that all 4 wheels of the car

are being powered by the engine, generally
providing more grip in slippery situations.
Manufacturers known for their prowess in this
particular drive type are Audi and Subaru, Audi in
particular having really pioneered the movement
through their early Quattro rally cars.  The benefits
are numerous, more grip in the snow/rain/loose
surfaces, extreme dry circumstances and generally
even tire wear among others, but you do sacrifice
gas mileage as there are more wheels that need to
be powered by the engine.  Most would consider
vehicles with AWD a great all-around vehicle for those needing one car to do it
all through all 4 seasons.

Front wheel drive is where the engine only powers the front two wheels.  This is
generally considered to the most common type of drivetrain, accounting for a
vast majority of vehicles on the road because of its low cost and simplicity, and
is found in popular vehicles such as the Toyota Camry, Honda Accord and
others.  Front wheel drive vehicles can be more compact, and often have better
legroom in the rear as they don’t require any mechanicals in the rear of the
vehicle as in rear wheel drive or all-wheel drive.  Additionally, front wheel drive is
much easier to control in inclement conditions as you don’t have to worry about
the rear end swinging out every time you touch the throttle. The downsides to
FWD are few, but they generally have a greater turning radius as a result of
having the driven wheels also do the turning, and they often exhibit what is called
torque steer, which means in rapid acceleration the car will pull to the left or the
right.

CHASSIS UNIT

The remaining parts which are not directly

involved in the development and
transmission of engine power to the wheels
is called the chassis unit. It maintain the
smooth transmission of the engine power
and supports the proper operation of the
car. The automotive chassis includes the
suspension, steering and braking systems.
It also consists of the frame, active
suspension including the springs shackles,
shock absorber, stabilizer, radius rods and
balances, and wheels and tires. The tires
provide the contract between the vehicle and the road.
 Activity 1.2

Name: ________________________________ Date: ___________

Strand: _________________________________ Score: __________

Direction: answer the following questions. Write your answer on the space provided.

1. What is the main function of the power or drive train?

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2. Name the components of the automotive power or drive train.

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3. What is the main function of the chassis unit?

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4. Give the components of automotive chassis

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5. Explain briefly the meaning of all-wheel drive engine.

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Activity 1.3

Name:________________________________ Date: ___________

Strand:_________________________________ Score: ___________

1. Draw and label power drive train unit

Lesson 2

Learning objectives
a. Define clutch and its component.
b. Discuss the importance of functions of clutch.
c. Explain function of its part
d. Draw and label clutch assembly

The clutch assembly

An automotive clutch is used to connect and disconnect the engine and manual
transmission or transaxle. The clutch is located between the back of the engine and the
front of the transmission.
The clutch is the first drive train component powered by the engine crankshaft.
The clutch lets the driver control power flow between the engine and the transmission or
transaxle. Before understanding the operation of a clutch, you must first become familiar
with the parts and their functions. This information is very useful when learning to
diagnose and repair the clutch assembly.
A clutch release mechanism allows the operator to operate the clutch. Generally,
it consists of the clutch pedal assembly, a mechanical linkage, cable, or hydraulic circuit,
and the clutch fork. Some manufacturers include the release bearing as part of the clutch
release mechanism.

Clutch
 Allows the engine to be disengaged to the transmission for shifting gears and
coming to stop.
 Allow smooth engagement of engine transmission.

Operation of Clutch
 Disengaged
 When the engine is running, the flywheel is rotating. The pressure plate attached
to the flywheel so the pressure plate also rotates. This friction disc is located
between the two.
 When the clutch pedal is released, the driver has push down on the clutch pedal.
This action forces the friction disc to move away to the pressure plate. No power
transmitted to the clutch.
 Engaged
 When the driver release the clutch pedal, power can flow through the clutch.
Spring in the clutches forces the plate against the friction disc. This action clamps
the friction disc against tightly between the flywheel and the pressure plate.
  Now the pressure plate and the friction disc rotate with the flywheel. The friction
disc assembled on a splined shaft that carries the rotary motion to the
transmission.

Clutch system

Parts of Clutch System

Friction disc a critical component of the clutch. It

has the role of connecting a rotating part (engine
flywheel) to another part which could be stationary
or rotating (pressure plate).

Flywheel a rotating mechanical device that is used to

store rotational energy.

Pressure plate
The clutch pressure plate is an important part of your
manual vehicle's clutch system. It is a heavy
metal plate that is controlled by springs and a lever. Its
main purpose is to apply pressure to the primary clutch
plate (or clutch disc), holding it against the engine
flywheel.

Release Bearing
The responsible for allowing the clutch to engage the engine
and disengage the engine?
The clutch fork and connecting linkage convert the
movement of the clutch pedal to the back and forth
movement of the clutch throw-out bearing. This action
allows the pressure plate's springs to force against the clutch disc, engaging the clutch to
the flywheel.

Bell housing a colloquial/slang term for portion of the

transmission that covers the flywheel and clutch.

Pilot Bushings
Pilot bearings and bushings serve as a guide and seat for the
transmission input shaft during engagement and disengagement
when the flywheel and pressure plate assembly turn at speeds
different than the input shaft and disc assembly, the pilot bearing
rotates.

The clutch Pressure Assembly

A typical pressure assembly consist of the clutch cover, pressure plate, pressure springs,
release lever or clutch finger, and adjusting crew.

1. Clutch cover. A thin metal cover enclosing the different parts of the clutch. It is
bolted to the engine flywheel thus holding the pressure plate, pressure spring,
release levers and adjusting screw.

2. Clutch pressure plate. This plate is made up of cast iron, the smooth side of
which presses the clutch disc against the surface of the flywheel.

3. Clutch pressure spring. It hold the clutch firmly against the surface of the
flywheel. Pressure springs are installed to provide pressure on the disc. Some
models have 3 pressure spring while others have th6 or 9 pressure springs.

4. Release lever or clutch fingers. There are release levers mounted in a clutch
cover by means of eyebolts or pins.

5. Adjusting screws. These are used for adjusting the correct level of the release
lever or clutch finger to achieve a uniform clearance between the disc and the
pressure plate when the clutch pedal is depressed.

6. Clutch disc assembly. This is shown in fig 2-A. as shown, it consists of clutch
lining or facings, cushion springs, torsional springs and spline hub or clutch hub.

7. Clutch lining. These are friction materials usually made of asbestos bonded or
riveted to the cushion springs.

8. Cushion spring. These are the steel plates where the lining are attached.

9. Torsional springs. These are the coil springs placed and riveted on the cushion
springs.
 10. Spline hub or clutch hub. This is riveted trough a flange at the center of the disc
in the cushion spring.

Activity 1.2

Name:________________________________ Date: ___________

Strand:_________________________________ Score: ___________

Direction: answer the following questions. Write your answer on the space provided.

11. What is the main function of clutch?

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12. What are the components of clutch?

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13. What is the function of adjusting screw?

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14. Explain the purpose of clutch lining.

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 15. How does friction clutch operate?

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Activity 1.2

Name: ________________________________ Date: ___________

Strand: _________________________________ Score: ___________

Direction: answer the following questions. Write your answer on the space provided.

________1. Used to connect and disconnect the engine and manual transmission or
transaxle.
________2. A rotating mechanical device that is used to store rotational energy
________3. It is a heavy metal plate that is controlled by springs and a lever. Its main
purpose is to apply pressure to the primary clutch plate (or clutch disc), holding it against
the engine flywheel.

________4. The responsible for allowing the clutch to engage the engine and disengage
the engine
_________5. Serve as a guide and seat for the transmission input shaft during
engagement and disengagement when the flywheel and pressure plate assembly turn at
speeds different than the input shaft and disc assembly, the pilot bearing rotates.

_________6. A colloquial/slang term for portion of the transmission that covers

the flywheel and clutch.
__________7. This is riveted trough a flange at the center of the disc in the cushion spring.

_________8. These are the coil springs placed and riveted on the cushion springs.

_________9. These are the steel plates where the lining are attached
_________10. These are used for adjusting the correct level of the release lever or clutch
finger to achieve a uniform clearance between the disc and the pressure plate when the
clutch pedal is depressed.

_________11. There are release levers mounted in a clutch cover by means of eyebolts or
pins.
_________12. This plate is made up of cast iron, the smooth side of which presses the
clutch disc against the surface of the flywheel.
_________13. A thin metal cover enclosing the different parts of the clutch. It is bolted
to the engine flywheel thus holding the pressure plate, pressure spring, release levers and
adjusting screw.

_________14. , it consists of clutch lining or facings, cushion springs, torsional springs

and spline hub or clutch hub.

_________15. an important part of your manual vehicle's clutch system. It is a heavy

metal plate that is controlled by springs and a lever. Its main purpose is to
apply pressure to the primary clutch plate (or clutch disc), holding it against the engine
flywheel
Lesson 3

Learning outcome

A. Explain the operation of hydraulic clutch system

B. Define different types of clutch
C. Discuss the procedures in bleeding hydraulic clutch system

Operation of the clutch

The operation of the clutch is based on the frictional contact between the surfaces
of the flywheel pressure plate and the clutch lining or facing of the clutch disc.
Depressing the foot pedal operate the clutch. See figure below.

Depressing the foot pedal, or clutch pedal, operate the clutch.

Type of clutch

1. Single dry plate. Single plate clutch is

mainly used in lightweight vehicles for
transmitting torque from an engine to
the input shaft. As per the name of this
Clutch it just has a single Clutch plate. 
 2. Multiple disc. This
type of clutch has
multiple clutch plates
that are used to
transmit power from
the shaft of an engine
to the transmission
shaft of the same
vehicle.

3. Wet disc. A clutch when operates within an oil bath then it is called
a wet clutch. On the other hand, a dry clutch operates without oil.

. 
4. Semi- centrifugal clutch. For keeping in the
engaged position, the semi-centrifugal
clutch uses spring force along with the
centrifugal force. Semi-Centrifugal Clutch
is made of a Clutch plate, Friction lining,
Levers, Pressure plate, Flywheel, and
Clutch springs.

5. Diaphragm spring clutch. For

engaging clutches, this type of
clutch generates pressure on the
pressure plate. This clutch is
made of a diaphragm on the
conical spring. The crown or finger
type spring is attached to the
pressure plate.

Hydraulic clutch

The working principle of vacuum and the hydraulic clutch is almost the same.
Although the significant difference between those is that, the hydraulic clutch
operates through the pressure of oil, on the other hand, a vacuum clutch
operates through a vacuum.

Working principle of Hydraulic clutch  

Oil is pumped to the accumulator from the reservoir through a pump by an
engineer. The connection between the accumulator and cylinder takes place by a
control valve.

The engine of the vehicle operates the pump. A switch controls the valve. Apart
from that, a linkage mechanism is used by engineers to establish the connection
between piston and clutch.

Hydraulic clutch linkage

Operation of the hydraulic-clutch linkage begins when the drivers depresses the
clutch pedal. This forces a push rod into the master cylinder (see fig. 9).
Pressurized fluid is then faced from the master cylinder, through a cylinder line, a
servo or slave cylinder. A servo is a device that converts hydraulics pressure to
mechanical movement.

Bleeding clutch hydraulic system

Any air trapped in the hydraulic system must be removed by bleeding the
hydraulic system. Bleeding is procedure that remove the air by draining part of
the fluid. Bleeding is also done after disconnecting any part or hydraulics lines.

Bleeding procedures

 Clean any dirt and grease from around the reservoir cap diaphragm under it.

 Fill the reservoir to the Full Mark with fresh, new fluid. Used the fluid specified
by the vehicle manufacturer. This is dot 3 brake fluid.

 Connect one end of a rubber tube to the bleed screw in the servo a slave cylinder.

 Immerse the other and in a half- full container of the specified fluid.
 Slowly pump the clutch pedal several times and then ask someone to apply a light
force to the clutch pedal.

 Loosen the bleed screw until fluid discharges from the tube into the container. A
bubbles can be seen in the fluid. As the pedal goes down to the floor, close the
bleed screw.

 Repeat the procedure until no more air bubbles appear in the fluid.
 Activity 2.1

Name:________________________________ Date: ___________

Strand:_________________________________ Score: ___________

Direction: answer the following questions. Write your answer on the space provided.

1. What is hydraulic clutch?

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_______________________________________________________________________
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2. What are the components of hydraulic clutch?

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3. What are the difference types of clutch?

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_______________________________________________________________________
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4. Explain the purpose of clutch bleeding.

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5. Explain the operation of hydraulic clutch?

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Activity 2.2

Name:________________________________ Date: ___________

Strand:_________________________________ Score: ___________

Direction: answer the following questions. Write your answer on the space provided.

________1. Used to connect and disconnect the engine and manual transmission or
transaxle.
________2. a rotating mechanical device that is used to store rotational energy
________3. It is a heavy metal plate that is controlled by springs and a lever. Its main
purpose is to apply pressure to the primary clutch plate (or clutch disc), holding it against
the engine flywheel.

________4. the responsible for allowing the clutch to engage the engine and disengage
the engine
_________5. serve as a guide and seat for the transmission input shaft during
engagement and disengagement when the flywheel and pressure plate assembly turn at
speeds different than the input shaft and disc assembly, the pilot bearing rotates.

_________6. a colloquial/slang term for portion of the transmission that covers

the flywheel and clutch.
__________7. This is riveted trough a flange at the center of the disc in the cushion spring.

_________8. These are the coil springs placed and riveted on the cushion springs.

_________9. These are the steel plates where the lining are attached

_________10. These are used for adjusting the correct level of the release lever or clutch
finger to achieve a uniform clearance between the disc and the pressure plate when the
clutch pedal is depressed.

_________11. There are release levers mounted in a clutch cover by means of eyebolts or
pins.
_________12. This plate is made up of cast iron, the smooth side of which presses the
clutch disc against the surface of the flywheel.

_________13. A thin metal cover enclosing the different parts of the clutch. It is bolted
to the engine flywheel thus holding the pressure plate, pressure spring, release levers and
adjusting screw.
_________14. , it consists of clutch lining or facings, cushion springs, torsional springs
and spline hub or clutch hub.
_________15. an important part of your manual vehicle's clutch system. It is a heavy
metal plate that is controlled by springs and a lever. Its main purpose is to
apply pressure to the primary clutch plate (or clutch disc), holding it against the engine
flywheel.
Lesson 4
Learning outcome
a. Define trouble causes of clutch assembly.
b. Appreciate the importance of trouble shooting of clutch.
c. Discuss clutch commonly troubles and its remedies.

Clutch trouble causes and remedies

The main purpose of the clutch assembly is to deliver engine power to the transmission,
that is, to disengage the power of the engine from the transmission when shifting of gears
is desired and to engage the power of power transmission after the shifting is done. When
the function is not fulfilled or there is rough transmission of power, the possible troubles
of the clutch are as follows:
1. Slipping clutch
2. Dragging clutch
3. Grabbing clutch
4. Noisy clutch
5. Abnormal wear of clutch facing or lining.
Slipping clutch
This is where no sufficient force is applied t the transmission when the clutch is applied.
Possible cause Remedies

 Improper adjustment of clutch  Adjust clutch pedal free play to

pedal. (too high) specification.

 Improper or unequal release of  Adjust release lever or clutch

lever height (adjustment not equal) finger to have equal pressure.

 Weak or broken pressure springs.  Replace weak and broken pressure

springs.

 Stuck or bent clutch linkage.  Check and repair or replace as

required.
 Warped pressure plate or flywheel.  Replace.
  Worn out clutch facing or linings.  Reface or replce linings.

 Greasy or oily clutch facing or

lining.  Wipe off with dry cloth.

Dragging clutch
A dragging clutch is one where the flywheel and pressure plate do not fully release the
clutch disc when the clutch is disengaged.

Possible cause Remedies

 Excessive clutch pedal free play  Adjust clutch pedal free play to
(clutch disc not fully released) specification.

 Improper or unequal release of  Adjust release lever or clutch

lever height (adjustment not equal) finger to have equal pressure.

 Weak or broken pressure springs.  Replace weak and broken pressure

springs.

 Stuck or bent clutch linkage.  Check and repair or replace as

required.
 Warped pressure plate or flywheel.  Replace.

 Worn out clutch facing or linings  Reface or replace linings.

Grabbing

A grabbing or chattering clutch will produce a very severe vibration or jerking

motion when the vehicle is accelerated from a standstill. Even when the
operator slowly releases the clutch pedal, it will seem like the clutch pedal is
being pumped rapidly up and down. A loud bang or chattering may be heard, as
the vehicle body vibrates.
Possible cause Remedies
 Glazed or harden lining  Replace
 Broken torsional spring  Replace with specified torsional
spring
 Grease on lining  Wipe it off with clean rag
 Crack pressure plate or flywheel  Replace
 Tight splines of clutch hun on clutch  Replace
shaft splines  Replace
 Worn out pilot bearing or bushing
 Too much play between gears  Repair or reface
Noisy clutch

Possible cause Remedies

When clutch is engaged:
 Loose spline on clutch hub  Repair or reface

 Loose or broken torsional spring  Replace

 Misalignment of engine and  Remove, check, and align

transmission
When dis engaged:
 Replace worn out and bearings and
 Worn out release bearing lubricate lubricate bearings
bearing
 Replace worn out parts and
 Worn out pivot bearing or bushing lubricate parts that need to be
lack of lubricant lubricated

Abnormal wear of clutch facings or linings.

Possible cause Remedies

 Insufficient pedal play.  Adjust to specification.

(slipping)

 Weak or broken pressure plate  replace.

 Badly warped pressure plate.  Replace

 Frequent riding on the clutch pedal  Educate the driver on the effect of
by the driver. clutch riding
 Activity 3.1

Name:________________________________ Date: ___________

Strand:_________________________________ Score: ___________

Direction: answer the following questions. Write your answer on the space provided.

1. Name the different troubles of the clutch. Identify each trouble.

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2. What are the possible causes of noisy clutch and what are the possible remedies?

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_______________________________________________________________________
_______________________________________________________________________
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3. What are the possible causes of slipping clutch and what are the possible
remedies?

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_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______

4. Abnormal wear of clutch facing or lining is the result of frequent riding on clutch
pedal by the driver. What is the remedy to avoid this problem?
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_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
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Activity 3.2

Name:________________________________ Date: ___________

Strand:_________________________________ Score: ___________

Direction: Enumerate the clutch trouble causes and its remedies. Write your answer on
the box provided.

1.

Possible cause Remedies

2.

Possible cause Remedies

3.
Possible cause Remedies

4.

Possible cause Remedies

Lesson 5
Learning outcome
1. Discuss correct procedures in removal, disassemble and installation of clutch
assembly.
2. Preparing tools and equipment in removal, disassemble and installation of clutch
assembly.
3. Observe safety in removal, disassemble and installation of clutch assembly.

Clutch removal, disassemble, and installation

CLUTCH TROUBLESHOOTING

An automotive clutch normally provides depend-able service for thousands of

miles. However, stop and go traffic will wear out a clutch quicker than highway
driving. Every time a clutch is engaged, the clutch disc and other components
are subjected to considerable heat friction and wear.

Operator abuse commonly causes premature clutch troubles. For instance,

"riding the clutch master cylinder, slave cylinder, and connections for a typical
hydraulic clutch (over slipping clutch acceleration), resting your foot on the
clutch pedal while driving, and other driving errors can cause early clutch
failure.

When a vehicle enters the shop for clutch troubles, you should test-drive the
vehicle. While the vehicle is being test-driven, you should check the action of
the clutch pedal, listen for unusual noises, and feel for clutch pedal vibrations.
Gather as much information as you can on the operation of the clutch. Use this
information, your knowledge of clutch principles, and a service manual-
troubleshooting chart to determine which components are faulty.
There are five types of clutch problems- slipping, grabbing, dragging, abnormal
noises, and vibration. It is important to know the symptoms produced by these
problems and the parts that might be the cause.

BEFORE INSTALLATION
Clutch Kit should be installed only on a specified vehicle. Perform installation according
to owner’s manual. For any unspecified procedures consult with vehicle service manual.

1. Before installation read owner’s manual.

2. Carefully remove parts required for the installation and store them in a clean, not dusty
environment.

3. Carefully disconnect and store connectors, wire couplings, etc.

4. Mark all temporarily removed parts to avoid any error during the installation later.

5. Disconnect negative terminal of the battery before beginning installation to prevent

electrical damage and/or shock.

6. Position jack/rigid rack/lift at the location specified by vehicle manufacturer.

7. Make sure to complete an examination of the vehicle after the installation.

System Inspection

System Inspection Examination of the removed clutch system components in many cases
can reveal the reason for the failure of the removed unit. If the removed clutch
components failed due to reasons other than normal wear or driver abuse, a close
inspection can identify the reason for failure, and prevent premature failure of the
replacement unit.

If oil is present on the facing of the clutch disc, check the rear main seal for leakage. If
the oil appears to be grease then examine the release bearing. It is possible the bearing
was continually rotating because of improper adjustment, or the driver was riding the
clutch pedal. There are some bearings that are designed to continually rotate, but for
those applications that are not designed to endure this, the bearing will become hot. The
grease will liquefy and saturate the facing. Also examine the quill of the transmission.
There may have been excessive grease placed on the quill, which contaminated the
facing.

Examine the input shaft of the transmission. Clean the shaft with a wire brush and
inspect. If there is excessive wear, replace the input shaft. For reinstallation, place a light
film of white lithium grease on the input shaft. Do not over lubricate. Excessive grease
will contaminate the disc facing.