A dry single-plate clutch with a central diaphragm pressure spring is installed on GAZelle Next cars equipped with a manual transmission.

The clutch is located between the engine and the gearbox.

It is designed to disconnect and connect the flywheel located on the engine crankshaft and the input shaft of the gearbox.

Конструкция сцепления автомобиля ГАЗель НекстКонструкция сцепления автомобиля ГАЗель Некст

The clutch consists of a driven (friction) disc, a clutch cover with a pressure plate and a diaphragm spring, and a clutch release mechanism.

The pressure plate is mounted in a stamped steel casing bolted to the engine flywheel.

The driven disk is installed on the splines of the input shaft of the gearbox and is clamped by a diaphragm spring between the flywheel and the pressure plate.

The hydraulic clutch release drive consists of a master cylinder and a slave cylinder, a clutch pedal, a hydraulic clutch release line and a connecting hose.

The clutch pedal is connected to the master cylinder by means of a pusher, which is equipped with an adjusting unit.

The spring returns the pedal to its original position.

The sensor informs the electronic engine control system about the position of the clutch pedal at any given moment.

The master cylinder is connected with a hose to a reservoir installed on the master brake cylinder (the reservoir is common for both master cylinders).

The hydraulic clutch release uses brake fluid.

Possible clutch malfunctions and remedies

Cause of malfunction (Remedy)

Incomplete disengagement of the clutch (clutch leads):

- Difficult movement of the driven disc hub on the splines of the input shaft of the gearbox

Clean the splines

- Warping of the driven disk

Replace driven disc

- The blades of the diaphragm spring do not lie in the same plane or are worn out

Replace pressure plate

- Air in the hydraulic clutch system

Upgrade the system

Incomplete engagement of the clutch (slipping, reduced acceleration dynamics):

- Reducing the force of the diaphragm spring

Replace pressure plate assembly

- Wear of friction linings, flywheel working surfaces and pressure plate

Replace the driven disc. Replace flywheel or pressure plate

- Oiling the friction linings of the driven disc

Eliminate the causes of oil ingress on the friction linings.

Replace driven disc

- Difficult movement of the driven disc hub on the splines of the input shaft of the gearbox

Clean the splines

- The blades of the diaphragm spring lie in the same plane or are worn out

Replace pressure plate

- Slow return of the working cylinder piston to its original position with the clutch pedal fully released; clogging of the expansion hole of the master cylinder or swelling of the cuff

Clean the cylinder from dirt or replace the seal

Incomplete clutch engagement (tangible jerks when engaging):

- Wear of friction linings

Replace driven disc

- Oiling the friction linings of the driven disc

Eliminate the causes of oil ingress on the friction linings.

Replace driven disc

- The blades of the diaphragm spring are not in the same plane or are worn out

Replace pressure plate

- Loss of elasticity of leaf springs and damper springs of the driven disc

Replace the driven disc

Increased noise and vibration during clutch operation:

- Breakage or loss of elasticity of the damping springs of the driven disc

Replace driven disc

- Lack of lubrication or defects in the clutch release bearing (release bearing)

Replace bearing or bearing sleeve

- Wear of a friction washer of a driven disk

Replace driven disc

The pressure in the clutch release drive is not held (when smoothly pressed, the pedal reaches the stop, but the clutch does not disengage):

- Dirt of the master cylinder or large wear of its mirror

Flush or replace the master cylinder

- Worn or damaged master cylinder piston cuff

Replace the cuff

- Leakage of liquid through the cuff of the working cylinder of the clutch release drive, violation of the tightness of the pipeline

Replace the collar or slave cylinder, tighten the pipeline fastener

- The presence of air in the hydraulic drive of the clutch release

Pump the drive, bleed the air

Increased clutch noise during engine operation:

- Lack of lubrication or defects in the release bearing

Replace bearing or bearing sleeve

- Loose tightening of the clutch release hydraulic drive connections

Tighten connections

Squeak of clutch pedal bushings:

- Lack of grease in the plastic bushings of the clutch pedal

Lubricate the bushings with graphite grease

- Wear of the clutch pedal plastic bushings

Replace bushings

- Breakage or loss of elastic properties of the return spring

Replace the spring

Changing fluid and bleeding the clutch

Due to the fact that the clutch release hydraulic drive and the service brake system are united by one reservoir, the replacement of the working fluid in the clutch release hydraulic drive occurs when changing the brake fluid in the brake hydraulic drive.

According to the manufacturer's recommendation, the fluid should be replaced after thirty thousand kilometers or 2 years of operation (whichever comes first)

The hydraulic clutch release uses DOT-4 brake fluid.

This liquid is hygroscopic (it quickly absorbs moisture from the air).

Condensation formed in the main and working cylinders causes corrosion of parts and failure of the hydraulic drive, therefore we recommend replacing the fluid regardless of the mileage.

Замена жидкости и прокачка сцепления

Remove the protective cap from the bleed valve on the clutch slave cylinder.

We put a hose on the valve and lower its end into a container with a small amount of brake fluid.

Ask the assistant to sharply press the clutch pedal four to five times at intervals of one to two seconds, and then hold it down.

Unscrew the valve ¾ turn.

Old (dirty) liquid will flow from the hose into the container.

As soon as the liquid stops flowing out, we twist the air release valve.

Constantly monitor the fluid level in the reservoir, not allowing it to drop to the "MIN" mark on the reservoir wall, since at a lower level you may not notice the moment when the clutch release section in the reservoir is completely drained and air will enter the system.

In this case, the hydraulic drive will have to be pumped. Top up with new brake fluid if necessary.

Thus, a gradual displacement of the old fluid by the new one is ensured without draining the hydraulic system.

We repeat the operation until the liquid is completely replaced (a clean liquid without air bubbles should flow out of the hose).

After replacing the fluid, put on the protective cap on the release valve.

Add brake fluid to a level of 15-20 mm from the upper edge of the reservoir. We close the tank with a stopper.