Advantages of PHC Valeo Clutch Disc

Feel minimize vibration and noise

PHC Valeo clutch disc uses dampers, large angular displacement one and multi stage pre-damper, to fit the car's circumstances. This makes it possible to reduce the unpleasant noise and vibration generated by changing revolution speed. Thereby, PHC Valeo clutch provides the most comfortable ride according to the vehicle's overall characteristics.

Start smoothly and drive safely

A vehicle using PHC Valeo clutch disc has better vehicle starts, and the driver enjoys a more comfortable ride due to their cushion phenomenon which affects the pedal release time and distance of disengagement. PHC Valeo clutch is indispensable for pleasant driving due to the firm's accumulated technology.

Certificate

IATF 16949 / ISO 14001/ OHSAS 18001

Clutch Disc Assembly

Clutch Disc Assembly Type

Classification by the existence and shape of torsion spring

• Rigid type: Disc without damper
• Torsion spring type: Disc with torsion spring as damper
• Torsion rubber type: Disc with torsion rubber as damper

Classification by the presence and shape of cushion plate

• Solid type: Disc without cushion function on cushion plate
• Plate cushion type: Disc with cushion plate
• Separate cushion type: Disc with multiple separate cushion plate
• Tripod cushion type: Disc with a small wing shape to increase cushion plate or stiffness

Classification by characteristics

• Main damper type: A disc with damper
• Pre damper type: Main damper type but a disc with low stiffness and low damper characteristics

Clutch Disc Type

• 

  X Type clutch disc

  • Suitable for small seize passenger vehicles
  • Can be used as a main damper or pre damper type
• 

  Z Type clutch disc

  • Suitable for small & medium size passenger vehicles
  • Can be used as a main damper or pre damper type
• 

  KJ Type clutch disc

  • A product with wide angle is suitable for medium size passenger vehicle & light commercial vehicles
  • Can be used as a main damper or pre damper type
• 

  Rigid type clutch disc

  • A product without damper is suitable for medium size passenger vehicles & SUV(Sport Utility Vehicle)
  • Can be used with DMF(Dual Mass Flywheel)
• 

  KCTR Type clutch disc

  • Suitable for vehicles requiring high hysteresis such as diesel-powered passenger vehicles
  • A product applied with rubber instead of torsion spring
  • Can be used as a main damper or pre damper type
• 

  WX Type clutch disc

  • A product with wide angle is suitable for medium size passenger vehicle & light commercial vehicles
  • Can be used as a main damper or pre damper type
• 

  SX Type clutch disc

  • A product with wide angle is suitable for medium size passenger vehicle & light commercial vehicles
  • Can be used as a main damper or pre damper type

Marking & Details on Clutch Disc

Box Details

Brand logos are flexible depending on the market.

Label Details

Troubleshooting

• Excessive wear and breakaway of a torsion spring [noise]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Quick start and sudden braking
  • Excessive use of an engine brake

  Maintenance & caution

  • Replace a clutch disc
  • Repair transmission
  • Refrain from quick start and sudden braking

• Excessive wear of a facing [slip]

  

  Causes

  • Excessive use of an engine brake
  • Missing disc replacement time
  • Excessive use of a half clutch

  Maintenance & caution

  • Replace a clutch on a kit basis (disc, cover, bearing)

• Contaminated clutch disc [slip]

  

  Causes

  • Excessive application of grease on the teeth of a disc
  • Oil leak of an engine or a gear box

  Maintenance & caution

  • Replace a clutch disc
  • Check and remove contaminants
  • Apply a proper amount of grease on the teeth of a disc

• Damaged cushion plate [gear shift]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Poor arrangement of an engine gear box
  • Damaged pilot bearing
  • Driving overloaded
  • Excessive use of an engine brake

  Maintenance & caution

  • Replace a clutch
  • Rearrange the engine gear box

• Damaged clutch facing [gear shift]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Slip due to excessive driving or overload
  • Excessive(habitual) use of a half clutch
  • Defective clutch working system
  • Driving overloaded
  • Excessive use of an engine brake

  Maintenance & caution

  • Replace a clutch

• Damaged edge of a subplate [gear shift]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Excessive use of an engine brake
  • Excessive pedal manipulation
  • Reverse assembly of a clutch disc

  Maintenance & caution

  • Replace a clutch cover / a flywheel
  • Readjust the clutch working system (pedal height, self-control system, clutch combination etc.)
  • Right installation of a clutch disc

• Damaged teeth of a clutch disc [gear shift]

  

  Causes

  • Damaged teeth by a main shaft
  • Poor sliding due to stabbing
  • Poor transverse vibration due to stabbing

  Maintenance & caution

  • Use a home position zig when installing a disc
  • Maintain home position when installing a transmission

• Deformed clutch disc [gear shift]

  

  Causes

  • Careless transport and handling
  • Poor assembly when installing

  Maintenance & caution

  • Replace a clutch disc
  • Caution required for handling and storing
  • Don’t load under weight

• Excessive wear of the teeth of a clutch disc [gear shift]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Excessive shaking of an engine crank shaft (flywheel)
  • Wear due to deterioration of a main shaft
  • Excessive use of an engine brake

  Maintenance & caution

  • Replace a component after checking the shaking of the engine crank shaft
  • Check the level of deterioration of the transmission
  • Check the level of wear of the main shaft

• Damaged disc due to over torque [gear shift]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Excessive use of an engine brake
  • Quick start and sudden braking
  • Excessive clutch pedal manipulation
  • Use of an incorrect item

  Maintenance & caution

  • Replace a clutch disc

Clutch Installation Guide

Clutch Removal

• Mark drive shafts to match up on reassembly.
• Fully support transmission making sure that it’s securely fastened to transmission stand. Do not allow gearbox to hang on the input shaft.
• Remove gearbox directly backward but not diagonally.

For Best Results

• Install new release bearing and pilot bearing/bushing whenever installing a new clutch
• Replace clutches as KIT
• Surface of the pressure plate & flywheel should be even or flat.

Inspection & Checkpoint

Checking abnormality before replacement is important, i.e. checking hydraulics, bearing, clutch cable, oil leakage etc.
Make sure new products are exactly for your application.
If try to engage any same size clutch to your mission,

A. facing

No oil or contamination on facing is allowed.

B. clutch disc

Check spline teeth or flywheel runout.

Apply 'little' grease on teeth and drive shaft spline.

C. flywheel

Check overheating crack, scoring, warping and contact surface(with facing) flatness.

D. input shaft

Check spline wear. Apply little grease on the teeth.

E. release bearing

Remove old grease/Apply thin grease. New bearing must slide freely.

Apply thin grease on fork pivot and fingers. Ensure smooth operation.

Installation

• Make flywheel/pressure plate/disc facing absolutely clean(No dust or rust using solvent or cleaner)
• Use alignment tool to correctly align the disc to flywheel.
• Assemble cover to flywheel dowel holes. Tighten bolts evenly according to diagonal order.
  Flywheel to crank(8 bolts)53 ft. lbs.
• Install transmission housing carefully. Input shaft slowly with care as first picture shown above.
  DO NOT FORCE or use the tightening of the bell housing bolts to draw transmission to the engine block.
  Rotate input shaft if necessary to align splines.
  DO NOT HANG transmission jack lift, during installation.
• Refer to the vehicle manufacturer's specifications for correct adjustment of the clutch.
• After adjusting clutch pedal release distance and hydraulics, take a load test.

Production process

The Highest Quality for Customer Satisfaction

PHC Valeo has made unstinting investment in equipment to manufacture the best product for customer's satisfaction. We're realizing zero defects through building the newest cutting-edge automatic production system and production management which all processes are visible.

Also, we provide the optimal working environment with locating the equipment ergonomically for the workers. We have especially raised the efficiency of the working environment and lowered the dangers, utilizing CoBot. That is, we offer the optimal working environment which is the base of manufacturing products of zero defects.

Safety precautions

Handle with care

Do not drop or touch with oily hands.

Check for smooth installation

Check if the disc slides smoothly into the shaft before final assembly.

Remove excess grease

Remove any excess grease on the input shaft coming out through the disc hub.

Diagonal bolt tightening

Gradually tighten the bolts in diagonal directions.

Check alignment of clutch and transmission

Check the alignment of the clutch set, especially the disc: do not force the disc onto the shaft.

Warning

• Do not use this clutch for racing, high performance driving, hot rodding, or any situation whenever engine RPMs may exceed manufacturer's specifications for the engine.
• The pressure plate can explode unexpectedly causing serious injury or death to vehicle occupants and bystanders.
• The clutch cover and bell housing will not protect from exploding the pressure plate.
• Always use the recommended clutch set for your specific application.

Product Information