■ COMPANY: VALEO SERVICE (UK) ■ STAND NUMBER: C22
What are the main reasons for warranty returns?
1. The clutch friction plate input shaft splines have been damaged.
This damage can occur for a number of reasons, including incorrect alignment of the gearbox to the engine during assembly or the splines on the gearbox input shaft were not aligned correctly or are in poor condition.
This issue will only occur during reassembly, so attention must be paid when refitting the gearbox.
Installers must ensure the gearbox input shaft is in line with the engine crankshaft and the shaft is perpendicular with the flywheel. A gearbox support will be beneficial as it allows the gearbox to be at the correct alignment while the splines are fine-tuned into position.
As the input shaft is being offered into the drive plate hub, ensure the splines on the two parts are matching up and are guided in until the engine and gearbox are fully secured together.
2. Grease contamination on the clutch friction plate.
This mainly occurs due to too much, or incorrectly applied grease being applied to the friction plate input shaft splines, which has then radiated outwards due to centrifugal force whilst the clutch is in operation.
If it is necessary to apply grease during clutch fitment, coat the gearbox input shaft with the correct grease then wipe the excess off, leaving only a thin film. If too much grease is applied when the input shaft is rotating at engine speed, it will force the grease outwards onto the clutch drive plate and pressure plate, causing juddering or slipping. To reduce the chance of this, always use the correct, high temperature grease, suitable for use in clutch environments.
Valeo supplies a sachet of grease in most of its clutch kits – you should use ONLY the grease provided to sparingly lubricate the release bearing guide, fork bearings and primary shaft pilot bearing or bushing. Copper-based grease is unsuitable due to its low viscosity and melting temperatures.
How important is product handling?
Even though Valeo performs stringent packaging and damage tests on its units, it is often forgotten that the product inside the box is not designed to take direct impact. The way that a product is stored before sale and handled prior to fitment can have consequential impact on how it performs on the vehicle.
It is recommended that all products be kept in a clean, dry area and are kept in an upright position. Placing units on their sides can cause damage to things like mounting brackets on headlights, return straps on clutches and tanks on radiators.
What fitting advice would you give to technicians?
Although there are general fitting techniques when assembling parts to vehicles, it is important to keep in mind that there are different types of technology on all motor vehicle components.
When fitting a clutch or CSC, for example, how you fit it depends on the type of technology or design of the unit.
Valeo recommends you always check the VM specification before fitting the unit. This will inform you if a specific fitting tool is required and how to apply the correct method of fitment.
Visit Valeo on Stand C22 at MECHANEX Donington Park (October 6/7) to find out more about its comprehensive product range.
Registration is simple, visit http://www.mechanex.info or call 01923 237799. For all the latest news and info on upcoming shows, follow @MechanexShow.
