Advantages of PHC Valeo Clutch Cover

Suitable for a variety of vehicle types

PHC Valeo clutch cover generates a pushing load and determines the pedal effort of the driver. This makes PHC Valeo clutch cover provides a variety of Clutch covers suitable for vehicles from light passenger vehicle to heavy-duty truck.

Ensure a smooth drive

PHC Valeo clutch cover is categorized according to shape and part composition. This features that each type has a unique characteristic so that it guarantees a smooth start and a good drive.

Certificate

IATF 16949 / ISO 14001/ OHSAS 18001

Clutch Cover Assembly

Clutch Cover Assembly Type

Classification by pressure parts

• Diaphragm Spring Type: It uses a single diaphragm spring instead of coil springs and has constant pressure characteristics.
• Coil Spring Type: It uses small coil springs similar to valve springs.

Classification by direction of release load operation

• Push type: On pressing the pedal, the release bearing pushes the diaphragm fingers to disengage the clutch. It's a common type due to ease of assembly and wide range of applications.
• Pull type: It disengages the clutch using a pulling motion instead of a pushing one and applied to vehicles that prefer a relatively large clutch lever ratio.

Clutch Cover Type

• 

  CP Type Clutch Cover

  • CP type clutch cover employs world-patented technology while shifting gears lower the pedal effort, thus permit easy clutch adjustment and more convenient ride.
  • Widely used product, it supports diaphragm spring with fulcrum plate.
  • It's suitable for passenger vehicles.
• 

  ED Type Clutch Cover

  • ED type clutch cover supports diaphragm spring with hook sub assembly.
  • It improves the characteristics of pressure plate lift and has a reduction effect of the release load hysteresis.
  • It's suitable for light & medium-sized passenger vehicles.
• 

  DT Type Clutch Cover

  • DT type clutch cover, a pull type, has high clutch cover ratio.
  • It's suitable for medium-sized passenger vehicles
• 

  DBC Type Clutch Cover

  • DBC type clutch cover supports diaphragm spring with fulcrum plate and river.
  • It's suitable for light commercial vehicles.
• 

  DBR Type Clutch Cover

  • DBR type clutch cover supports diaphragm spring with fulcrum plate and delta river.
  • It's suitable for high-powered passenger vehicles and SUVs.
• 

  SAT Type Clutch Cover

  • SAT type clutch cover employs the self adjusting technology, thus it increases the clutch life cycle and improves performance.
  • It's suitable for high-powered vehicles and SUVs.

Marking & Details on Clutch Cover

Box Details

Brand logos are flexible depending on the market.

Label Details

Troubleshooting

• One-sided contact of the finger part [noise]

  

  Causes

  • Poor arrangement of the engine and transmission
  • Reuse of a worn-out release bearing
  • Eccentric force of a release bearing(deviation from the center)
  • Oversized clutch pedal stroke

  Maintenance & caution

  • Replace a release bearing
  • Maintain the engine and transmission

• Excessive wear of a diaphragm spring [noise]

  

  Causes

  • Defective clutch working system
  • Oversized clutch pedal stroke
  • Reuse of the existing bearing
  • Poor pedal working

  Maintenance & caution

  • Readjust the clutch working system (pedal height, self-control system, defective clutch etc.)
  • Replace a clutch

• Hot spots on a pressure plate [slip]

  

  Causes

  • Contamination of clutch’s friction material and pressure plate by oil or grease
  • Sudden gear shift when the engine is high-revolving
  • Excessive use of a half clutch
  • Oil leak

  Maintenance & caution

  • Replace a clutch
  • Check and remove contaminants
  • Don’t apply grease too much to the counter part
  • Don’t use gloves with oil

• Slip of a clutch [slip]

  

  Causes

  • Sudden gear shift when the engine is high-revolving
  • Contamination of the friction surface by grease
  • Excessive use of a half clutch
  • Use of an incorrect item

  Maintenance & caution

  • Replace a clutch
  • Refrain from using a half clutch
  • Refrain from quick start and sudden braking

• Excessive wear of the friction surface of a pressure plate [slip]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Sudden gear shift when the engine is high-revolving
  • Excessive wear of a disc facing
  • Quick start and sudden braking
  • Excessive use of an engine brake
  • Excessive use of a half clutch

  Maintenance & caution

  • Replace a clutch cover
  • Refrain from using a half clutch
  • Refrain from quick start and sudden braking

• Damaged pressure plate [gear shift]

  

  Causes

  • Occurrence of slip due to the excessive use of a half clutch
  • Sudden gear shift when the engine is high-revolving
  • Contamination of the friction surface by grease
  • Quick start and sudden braking
  • Excessive use of an engine torque
  • Driving overloaded

  Maintenance & caution

  • Replace clutch cover
  • Follow the maintenance guideline

• Interference due to an oversized pedal stroke [gear shift]

  

  Causes

  • Oversized clutch pedal stroke
  • Poor cylinder working
  • Poor pedal working

  Maintenance & caution

  • Replace a clutch
  • Inspect the clutch working system

• Damaged clutch cover [gear shift]

  

  Causes

  • Careless handling of a cover assembly (drop)

  Maintenance & caution

  • Replace a clutch cover

• Damaged clutch strap [gear shift]

  

  Causes

  • Sudden change of a gear while driving(Ex : 5th→3rd/2nd)
  • Dropping product due to careless handling
  • Poor product loading
  • Excessive use of an engine brake

  Maintenance & caution

  • Replace clutch cover
  • Refrain a sudden gear shift

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