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Dual clutch, component description

Dual clutch, component description
General
Gear shifting
Installation
Overview
Clutch disc
Diaphragm spring
Spring straps
DCCA
Sensor unit
Mechanical function
Clutch interaction
Clutch engagement
Clutch one and clutch two disengaged
Clutch one engaged
Clutch two engaged
Service considerations
Remove
Install
Clutch disc wear
Related information

Dual clutch, component description

General

The dual clutch unit (1) consists of two clutches: one clutch for odd numbered gears and one for even
numbered gears. The clutches are connected to two different input shafts and they are manoeuvred
by actuators in the DCCA (Dual Concentric Clutch Actuator) (2) . The DCCA is pneumatically
controlled via valves in the DCVU (Dual Clutch Valve Unit) (3) . Follow the link to "Gearbox,
mechanical, component description" under "Related information" for more information.

WARNING

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Risk of serious injury.

A highly compressed spring constitutes an extreme safety risk.
▶ The dual clutch unit must not be disassembled. It must be replaced as a complete unit. Since
clutch two is engaged in a non-pressurised condition, the diaphragm spring for clutch two is
preloaded, which makes it dangerous to open up the dual clutch unit.

Gear shifting
By using two clutches, the "next gear" is always pre-selected and gear shifting is just a matter of
disengaging one clutch and engaging the other. The TECU (Transmission Electronic Control Unit) (4)
controls the gear shifting process, and the gearbox enables shift from one gear to another without
torque interruption.

Installation

The dual clutch unit (1) is bolted onto the engine’s flywheel (2) . The dual clutch unit is the major part
of the rotating mass.

Note
For further information regarding repair method, see the related operation.

Overview
Overview

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1 Clutch one
1A Clutch disc, clutch one
1B Pressure plate, clutch one
1C End plate and diaphragm spring, clutch one
2 Clutch two
2A Clutch disc, clutch two
2B Pressure plate, clutch two
2C Housing and diaphragm spring, clutch two
3 Intermediate pressure plate
4 DCCA

Note
The dual clutch unit must not be disassembled. It must be replaced as a complete unit.

The dual clutch unit is an assembly that consists of two clutch discs (1A) and (A2), two pressure
plates (1B) and (2B) and two diaphragm springs (1C) and (2C).
It also consists of one intermediate pressure plate (3), which serves as friction surfaces for both
clutches.

Clutch disc
Disc

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1 Shock absorbing springs

2 Hub
3 Lining
4 Frictional element
5 Steel segments
The clutch disc is a dry disc with linings on both sides. It comprises a disc, shock absorbing springs, a
hub and linings.
The linings are asbestos-free material riveted to the disc.
The disc is connected to the hub via frictional element and shock absorbing springs to dampen the
pulsating torque delivered by the engine.
The hub is splined and can therefore move back and forth on the shaft.
To equalize the pressure on the linings, the disc consists of a number of steel segments, which also
helps to soften the action of the clutch.

Diaphragm spring
The diaphragm spring is a slotted spring-steel plate and its movement is transferred to the pressure
plate.

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The diaphragm spring for clutch two is connected to the support ring (3) on the actuator piston for
clutch two with a clamp (2) , which is tightened by a screw (1) .

Note
The clamp must be opened by releasing the screw (1) before removing the gearbox from the
engine. See "Assembly considerations".

The screw (1) can be accessed through one of the two holes on the clutch housing and through
openings in the dual clutch unit.

Note
For further information regarding repair method, see the related operation.

Spring straps
Overview

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Clutch one

1 Fixing at intermediate pressure plate for spring strap (2)

2 Spring strap, for pressure plate clutch one
3 Fixing at pressure plate for spring strap (2)
4 Connection screw for diaphragm endplate and pressure plate
5 Fixing at diaphragm endplate for spring strap (6)
6 Spring strap, for end plate
7 Fixing at housing for spring strap (6)

Clutch two

8 Fixing at pressure plate for spring strap (10)

9 Fixing at housing for spring strap (10)
10 Spring strap, for pressure plate clutch two
The spring straps enable the pressure plates to move axially. Furthermore, the straps transfer torque
from the pressure plates and facilitate the separation of the pressure plates and the clutch discs
during clutch engagement and disengagement.
When disengaging clutch one, the spring strap (2) facilitates the complete disengagement of the
pressure plate and the diaphragm spring end plate, which are connected by the screws (4). The
spring strap is fitted to the pressure plate at one end (3) and to the intermediate pressure plate at the
other end (1). Additionally, there is a spring strap (6) fitted between the diaphragm spring end plate
(5) and the housing (7).
When clutch two is engaged, full engagement of the pressure plate is facilitated by the spring strap
(10). The spring strap is fitted to the pressure plate at one end (8) and to the housing at the other end
(9).

DCCA
Overview

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1 Actuator piston, clutch one

2 Actuator piston, clutch two
3 Actuator housing
4 Spring
5 Sensor unit with position and air pressure sensors
6 Locking pin with screw
The DCCA consists of two individually operated clutch actuator pistons, (1) and (2), in the actuator
housing (3) which is fixed to the clutch housing. The actuator piston for clutch one (1) is moving
towards the engine when pressurised. The actuator piston for clutch two (2) is moving away from the
engine when pressurised.
The pistons are spring-loaded (4) to eliminate play between the actuator and the diaphragm springs.
The locking pin (6) is used to temporarily hold the piston for clutch two in its outermost position during
clutch installation. See "Service considerations".
Sensor unit
The pistons are continuously monitored by one position sensor and one air pressure sensor
respectively. The sensors, located in the sensor unit (5), monitor the operation of the DCCA and
measure the clutch wear.
The clutch actuator pistons are controlled pneumatically by the DCVU.Follow the link to "Gearbox,
mechanical, component description" for more information.

Note
For further information regarding repair method, see the related operation.

Mechanical function
Overview

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1 Input shaft, clutch one

2 Input shaft, clutch two
3 Flywheel
4 DCVU
5 DCCA
6 TECU
The clutch actuator, DCCA (5), is located concentrically around the two gearbox input shafts, (1) and
(2), and is operated pneumatically by the DCVU (4). The TECU (6) controls the solenoid valves in the
DCVU (4) to supply the DCCA (5) with air.
Clutch interaction
The dual clutch design enables the transmission to transfer power from one clutch to the other by
initiating the engagement of one clutch while the other clutch is still engaged. The degree of clutch
slip is precisely controlled to provide a smooth transfer of engine power without torque interruption
(powershift).

Clutch engagement
Overview

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State Clutch one Clutch two

Disengaged (air chamber Disengaged (air chamber
1
vented) pressurised)
Engaged (air chamber Disengaged (air chamber
2
pressurised) pressurised)
Disengaged (air chamber
3 Engaged (air chamber vented)
vented)
The DCCA encloses one air chamber for each clutch actuator piston. This set-up enables individual
control of clutch one and clutch two respectively.
Apart from the instantaneous conditions where both clutches are partially engaged (during
powershift), there are three predominant states.
● Clutch one and clutch two disengaged (1).

● Clutch one engaged (2).

● Clutch two engaged (3).

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Clutch one and clutch two disengaged

Operation
The chamber (1) for clutch one is vented. The actuator piston (2) is pushed away from the engine by
the diaphragm spring (3) releasing the pressure plate (4) to disengage the clutch.
The chamber (5) for clutch two is pressurised. The actuator piston (6) is pushed away from the
engine, pulling the diaphragm spring (7) and releasing the pressure plate (8) to disengage the clutch.

Power flow

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Clutch one engaged

Precondition
Clutch two is disengaged or partially engaged with slip.

Operation
The chamber (1) for clutch one is pressurised. The actuator piston (2) is pushed towards the engine,
pushing the diaphragm spring (3) and pulling the pressure plate (4) to engage the clutch.

Power flow

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Clutch two engaged

Precondition
Clutch one is disengaged or partially engaged with slip.

Operation
The chamber (1) for clutch two is vented. The actuator piston (2) is pulled towards the engine by the
diaphragm spring (3) that is pushing the pressure plate (4) to engage the clutch.
Since clutch two is engaged in non-pressurised condition, the diaphragm spring for clutch two is
preloaded, which makes it dangerous to open up the dual clutch unit.

WARNING
Risk of serious injury.
A highly compressed spring constitutes an extreme safety risk.
▶ The dual clutch unit must not be disassembled. It must be replaced as a complete unit. Since
clutch two is engaged in a non-pressurised condition, the diaphragm spring for clutch two is
preloaded, which makes it dangerous to open up the dual clutch unit.

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Power flow

Service considerations
Overview

1 Clamp
2 Support ring
3 Spring
4 Actuator piston, clutch two
5 Locking pin with screw
6 Spacer pin

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Remove

CAUTION
Risk of material damage.
Risk of damage to the gearbox.
▶ The dual clutch unit is bolted to the flywheel and is also attached to the clutch actuator DCCA.
The clamp must be released before separating the gearbox from the engine.

Prior to removing the gearbox from the engine, the clamp (1), connecting the diaphragm spring for
clutch two to the support ring (2) on the clutch actuator piston (4), must be opened. Slackening the
clamp makes the actuator piston move inwards because of the spring force exerted by the spring (3).

Install
Prior to fitting the gearbox to the engine, the clutch actuator piston for clutch two (4) must be pulled
out and locked in its outer position with the locking pin (5). In locked position the spacer pin (6) rests
against the locking pin (5).

Note
For further information regarding repair method, see the related operations.

Clutch disc wear

When a new dual clutch unit is fitted, it must be calibrated to obtain the initial engagement position for
each clutch. The present engagement position for each clutch is continuously measured during
driving.
When the wear of any clutch disc exceeds 85%, a fault code is set in the TECU and a message
regarding clutch replacement is displayed in the driver information display.

Related information
For more information on the electrical architecture, refer to:
Wiring diagram
➠ Vehicle electronics overview, system description
Related components
Gearbox, mechanical, component description ➠ Gearbox, mechanical, component description

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