TIAGO AMT

TIAGO AMT Service Manual (Supplement)

The information provided in this manual is based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. C Copyright 2017 TATA MOTORS All rights reserved. The material in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS.

INTRODUCTION This supplement service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA TIAGO AMT. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. The contents which are not covered in this supplement workshop manual have to be read in TATA TIAGO workshop manual. This manual provides information about the following groups: Transaxle. Clutch Driveshaft AMT Kit Console Instrument Cluster Component Replacement Diagnostic DTC Manual In case of any further information / technical advice please refer to the Service Circulars / Bulletins issued periodically or please contact your nearest Customer support office or you can also write to us at: Tata Motors Limited Literature Development Cell PCBU Customer Support, K-Block, Sector 15 & 15°, PCNTDA, Chikhali, Pune-410 501 Maharashtra.

INDEX SR. NO GROUP 1 TRANSAXLE 2 CLUTCH 3 DRIVESHAFT 4 AMT KIT 5 CONSOLE 6 INSTRUMENT CLUSTER 7 COMPONENT REPLACEMENT MANUAL 8 DTC MANUAL

TA65 Star AMT TRANSAXLE (TA-65 Star AMT)

TA65 Star AMT INTRODUCTION: TRANSAXLE The vehicle has a transversely mounted engine and transaxle. This layout of engine is typical of front wheel driven car. The gear box and differential are integrated into a single housing termed as Transaxle. The drive is transmitted to front wheels from differential side gears through constant velocity shafts. The final reduction is done by a pair of helical gears. All the forward gears are synchromesh (with first and second double synchromesh and other gears single synchromesh) and reverse gear is sliding mesh. The gear shifting conforms to international H pattern, 5th and reverse being in line. All lay shaft gears are free on it without needle bearings. There is no pilot bearing for the input shaft and there are no control dimensions to be maintained on input shaft and lay shaft. Pinion is integral with the Lay shaft and all the gears on the Lay shaft are locked by circlips. Speedo Sensor is located on differential housing.

TA65 Star AMT CONTENTS 1 PRECAUTION............................................................................................................................................ 1 2 TRANSAXLE GENERAL INFORMATION ................................................................................................ 2 3 TECHNICAL SPECIFCICATIONS............................................................................................................. 3 4 TIGHTENING TORQUES .......................................................................................................................... 4 5 SPECIAL TOOLS ...................................................................................................................................... 5 A. CLUTCH ................................................................................................................................................ 5 B. TRANSAXLE.......................................................................................................................................... 5 6 DIAGNOSIS OF TRANSAXLE ................................................................................................................ 10 7 SERVICE SCHEDULE OF TRANSAXLE................................................................................................ 10 8 CUT SECTION OF TRANSAXLE............................................................................................................ 11 9 EXPLODED VIEWS OF TRANSAXLE.................................................................................................... 12 10 REMOVAL OF TRANSAXLE FROM VEHICLE...................................................................................... 21 11 TRANSAXLE TA65 STAR AMT DISASSEMBLY (ON BENCH) ............................................................ 24 12 SUB ASSEMBLIES ................................................................................................................................. 30 12 TRANSAXLE TA65 STAR AMT ASSEMBLY......................................................................................... 42

TA65 Star AMT 1 1. PRECAUTIONS: 2. Ensure that the engaging gears are properly seated over their respective lugs. 3. Ensure that the Shifter finger lugs of transaxle are in line with each other while assembling the top cover for AMT Kit. 4. Keep off the oil from clutch disc, flywheel and pressure plate surface. 5. Position properly the release bearing with the clutch release shaft. 6. Ensure that the oil seals are free from dust particles. 7. Use only recommended transaxle oil. 8. Do not reuse the oil seal, while assembling transaxle. 9. Lubricate drive shaft birfield and tripod joint only with grease gun as referred in manual. 10. Ensure that the boots are not damaged during assembly of driveshaft. 11. Assemble and remove the transaxle component bearings only with special tools. 12. Ensure proper fitment of inter locking balls in the transaxle.

TA65 Star AMT 2 2. TRANSAXLE GENERAL INFORMATION GENERAL DESCRIPTION TA65 star AMT is similar transmission as current TA65 star as regards the architecture of input shaft, lay shaft and differential final drive, bearings and oil seals. The transmission TA65* AMT provides five forward speeds and one reverse speed by means of three synchronizers and input shaft, lay shaft and reverse idler shaft and differential. All forward gears are in constant mesh engaged through synchronizers and reverse gear uses a sliding idler gear arrangement. All the synchronizers are mounted on lay shaft and engaged with gears on lay shaft. The lay shaft turns the final drive gear and differential assembly, thereby turning the front drive shafts which are attached to the front wheels. The complete Gear Shifting Mechanism is controlled by Mechatronic Gear Box & TCU (Transmission control unit). This is further transmitted through shifter dogs and shifter forks to the shifter sleeves and synchronizers. Interlock piece is provided to prevent double engagement of gears. Inhibitor is provided to block direct shift from 5th gear to Reverse gear which guides the shift lever towards 4th gear. Central detent is provided for distinct position of gears about neutral position. CHANGES AND BENEFITS OVER TA65: The major areas of change and benefits over TA65 are: 1. The internal and external gear shifting mechanism and arrangement. TA65 star AMT employees Auto Shift using AMT Kit in place of current cable shift. The advantages of Auto Shift over cable shift are: A manual transmission requires the driver to be engaged in shifting the gears, while an automatic transmission changes gears for you. coordinating between the clutch, throttle, and gears Driver can give more attention on Road instead of thinking about gear position. 2. Twin cone carbon lined synchronizers for first and second gears to replace single cone brass synchronizers. Benefits are improved shift smoothness, reduction in shift efforts and enhanced life of synchro cones. 3. Deletion of intermediate plate and its integration into housing front half. This has improved the housing rigidity and accuracy of gear train positioning thus helping reduction in noise level. 4. TA65 star front half housing is 10mm wider than of TA65 to accommodate increased inertia flywheel to reduce marching noise. Housings are strengthened as compared to TA65 by additional ribs. 5. Rear cover rubber seal is replaced by liquid rear cover in place of 3 bolts in TA65. Mechanical Speedo (pinion and gear arrangement) is replaced by contact less Speedo (A sensor and a toothed wheel). This is to improve reliability of Speedo mechanism and to reduce complexity in assembling transaxles.

TA65 Star AMT 3 3. TECHNICAL SPECIFICATIONS: TYPE Synchromesh on all forward gears and sliding mesh for reverse gear. OIL CAPACITY 1.8 Liters OIL SPECIFICATION GEAR OIL EP80W NEXT GEN SS6582 MODEL TA 65*-5/3.64 (5 speed) with overdrive manual GEAR RATIO GEAR PETROL 1st 3.64 2nd 1.95 3rd 1.27 4th 0.95 5th 0.77 REV. 3.58 FINAL DRIVE RATIOS 4.06 GEAR SHIFT PATTERN R Reverse N Neutral A Automatic Mode (Forward Gears) M Manual Mode (Forward Gears) "+" For Up Shift "-" For Down Shift S Sport Mode AMT UNIT:- Model : Mode of Actuation : Electronic Recommended Oil : TUTELA CS-SPEED Oil Capacity : 0.45 kg

TA65 Star AMT 4 4. TIGHTENING TORQUES: 1 6.3 2 mount bracket to block 5.8 3 11 member) 5.8 -mount transaxle to Hsg. Rear half (clamp withTransmission) 4.2 4 5.4 5 hell Hsg. Front half (clamp withTransmission) 5.4 C-mount-link to BIW 5.4 6 Starter motor mounting 2.4 7 Fuel Line Clamps 1.5 8 Transaxle mounting bolt 4.6 9 Top cover Mounting Bolts 2.1 to 2.5 10 Lay shaft and input shaft nuts 12.3 to 16.7 11 Rear cover mounting screws 2.1 to 2.5 12 Drain plug and filler plug 3 to 4.1 13 Rear cover Assembly mounting bolts 2.1 to 2.5 14 Front and Rear Half Housing bolts 2.1 to 2.5 15 Reverse Lever Bracket Mounting bolts 2.1 to 2.5 16 Cable Anchoring Bracket bolts to Housing 2.1 to 2.5 17 Speedo Sensor Mounting bolt on Housing 0.85 to 1.15 18 Input Shaft Cover Mounting bolts 0.85 to 1.15 19 Differential Crown Mounting bolts 8 to 9 20 Input and Lay shaft Bearing Lock Plate Screws 1.6 to 1.9 21 Finger Reverse Inhibitor Holding nut on Housing 0.8 to 1 22 Reverse Inhibitor Socket Head Cap Screw on Housing 1.6 to 1.9

TA65 Star AMT 5 5. SPECIAL TOOLS LIST OF SPECIAL TOOLS: CLUTCH SR NO TOOL DESCRIPTION TOOL IMAGE PART NO APPLICATION 1 Mandrill for clutch disc alignment 270258902501 TRANSAXLE SR NO TOOL DESCRIPTION TOOL IMAGE PART NO APPLICATION 1 Work stand 257358903701 2 Mounting plate transaxle on work stand 270258902610

TA65 Star AMT 6 SR NO TOOL DESCRIPTION TOOL IMAGE PART NO APPLICATION 3 Adapter for locking input shaft 270258902611 4 Drift for input shaft bearing (front) 270258902602 5 Drift for differential bearing outer race and speed gear 265758903507 6 Drift for driver shaft oil seal 270258902601

TA65 Star AMT 7 SR NO TOOL DESCRIPTION TOOL IMAGE PART NO APPLICATION 7 Fixture for holding gear on differential casing 270258902609 8 Puller for differential side bearing 270258902604 9 Drift for differential bearing inner race 270258902608 10 Rest pad 270258902612 11 Puller for differential side bearing 265158903506

TA65 Star AMT 8 SR NO TOOL DESCRIPTION TOOL IMAGE PART NO APPLICATION 12 Holder for removing input shaft rear bearing 270258902606 13 Holder for removing lay shaft rear bearing 270258902607 14 Drift for a) Lay shaft deep groove ball bearing b) Rear hub outer bearing seating on spindle 264158902601 15 Drift for input shaft rear bearing, lay shaft rear bearing 265158903308

TA65 Star AMT 9 SR NO TOOL DESCRIPTION TOOL IMAGE PART NO APPLICATION 16 Puller for deep groove ball bearing (front) input shaft 265758902801 17 Puller for deep groove ball bearing (rear) 270258903508 18 Removal of cylinder roller bearing from lay shaft front 270258902605 19 Drift for installation of lay shaft bearing 270258902603

TA65 Star AMT 10 6. DIAGNOSIS OF TRANSAXLE Gears Slipping out of mesh Worn out shifter fork Worn synchronizer sleeve / gears Weak or damaged carriers / springs Worn bearings on input shaft or lay shaft Worn chamfered tooth on sleeve and gear Replace Replace Replace Replace Replace sleeve and gear Hard Shifting Inadequate lubricant Distorted or broken clutch disc Damaged clutch pressure plate Replenish Replace Replace clutch cover Gear Crashing Noise Worn synchronizer ring Worn chamfered tooth on sleeve or gear Inadequate or insufficient lubricant Damaged or worn bearing (s) Damaged or worn gear (s) Damaged or worn synchronizer parts Loosening of bearing lock Replace Replace Replenish Replace Replace Replace Repair 7. SERVICE SCHEDULE OF TRANSAXLE Sr. No. Operation Kms PDI 1.5K 7.5K 15K 22.5K 30K 37.5K 45K 52.5K 60K 67.5K 75K 82.5K 90K 97.5K 105K 112.5K 120K 127.5K 135K 142.5K 150K Months 0 2 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 Transaxle 1 Replace transaxle oil 75K / 60M 2 Check AMT Kit oil level, it should be in between min. & Max. level when the vehicle is in standstill and ignition ON condition. Top up AMT kit oil if necessary. Every Servic e Brakes 1 Check front brake pads & rear brake linings. Replace if necessary 15K / 12M 2 Replace brake fluid Check brake system components for Leakages # 45K / 24M 3 Inspect & if necessary adjust handbrake setting 15K / 12M

TA65 Star AMT 11 8. CUT SECTION OF TRANSAXLE TA 65 STAR:

TA65 Star AMT 12 9. EXPLODED VIEW OF TRANSAXLE:

TA65 Star AMT 13 SR. NO. DESCRIPTION 01 TRANSAXLE ASSY WITH VEHICLE SPEED SENSOR 02 HOUSING ASSY;FRONT-HALF 03 HOUSING ASSY;REAR-HALF 04 CYL.PIN (HSG.FRT.HALF TO HSG.REAR HALF) 05 INPUTSHAFT COVER 06 OIL SEAL (INPUT SHAFT);CR INDIA 06 OIL SEAL (INPUTSHAFT) FENNER 06 "OFFER DRG" OIL SEAL (INPUT SHAFT) 06 OIL SEAL (INPUT SHAFT) CR 06 OIL SEAL (INPUT SHAFT) (M/S SIGMA NOK) 07 HEX SCREW M6X10 TS17070-8.8SS8451S2-Y 08 SUB.ASSY BRACKET (REV.) 09 COVER ASSY;INPUT SHAFT 10 SHAFT (REVERSE IDLER) 11 SUB ASSY INTERLOCK PIN 12 OIL SEAL (DRIVE SHAFT) WITH DUST LIP;CR 12 "OFFER DRG" OIL SEAL (DRIVE SHAFT) 12 OIL SEAL(DRIVE SHAFT)WITH DUST LIP;SIGMAN 13 HEX FL SCR M6X10 TS17070-8.8SS8451S2-Y 14 HEX FL SCR M8X22 TS17070-8.8SS8451S2-Y 15 HEX FL BOLT M8 16 ASSY HEX SCREW M6X18-Z3-8.8TS17207 17 LINEAR BEARING (INA) 17 OFFER DRG.LINEAR BRG.(SEL.SHIFT SHAFT) SR. NO. DESCRIPTION 18 CYL PIN 6m6X12 IS 2393 19 VEHICLE SPEED SENSOR - PROCOL 19 VEHICLE SPEED SENSOR - PADMINI 20 ASSY. CLUTCH RELEASE YOKE 21 BRACKET 22 HEX FLANGE SCREW (REAR COVER) 23 ASSY.REAR COVER 24 BUSH;UPPER (ON HOUSING) 25 SEALING WASHER 16X22 IS3175 CU 26 MAGNETIC DRAIN PLUG 27 FILLER PLUG 28 SEALING WASHER 8X14 IS3175 CU 29 KIT-CLUTCH REL MECH FITTED ON TRAN 30 H/FL BOLT M8X55 TS17070-10.9 SS8451S2-YH 31 OIL CHANNEL 32 HEX FL BOLT M8X38 TS17070-8.8SS8451S2-Y 33 OFFER DRG.- ASSY.CL.RELS.BRG.WITH SLEEVE 33 ASSY. CL. REL. BRG WITH SLEEVECL.AUTO 33 ASSY.CLUTCH RELEASE BEARINGVALEO(INDIG)N 34 CLUTCH RELEASE LEVER 35 H/FL BOLT M8X45 TS17130-8.8SS8451S2-Y 36 HEX FL NUT AM8 TS17430-8SS8451S2-Y 37 KIT-CLUTCH REL MECH FITTED ON TRAN 38 BUSH; LOWER (ON HOUSING). 39 TRANSAXLE ASSY WITH AMT

TA65 Star AMT 14 EXPLODED VIEW OF DIFFERENTIAL:

TA65 Star AMT 15 SR. NO. DESCRIPTION 01 ASSY DIFFERENTIAL COMP (65/16) 02 SUB ASSY DIFFERENTIAL (M/S BHAVANI IND) 03 SIDE BEVEL GEAR (M/s BHAVANI IND.) 04 BEVEL PINION (M/s BHAVANI IND.) 02 SUB-ASSY.DIFFERENTIAL (FOR SEDAN) 03 SIDE BEVEL GEAR (SONA) 04 BEVEL PINION (SONA) 05 SPIDER (FOR INDIGO) 06 EXT.CIRCLIP 15X1.5H IS3075P1 SS8400 07 TAPER ROLLER BEARING (INNER) 07 TAPER ROLLER BEARING (INNER) 07 TAPER ROLLER BEARING (INNER) 07 TAPER ROLLER BEARING (INNER) 07 TAPER ROLLER BEARING (INNER) 07 TAPER ROLLER BEASRING (INNER) 07 TAPER ROLLER BEARING (INNER) 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN SR. NO. DESCRIPTION 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 08 WASHER (DIFFERENTIAL) FOR SEDAN 09 SENSING WHEEL (CONTACTLESS SPEEDO) 10 GEAR FINAL DRIVE (65/16) 11 COLLARED SCREW 12 SHIMS (0.45) DIFF.BRG. 12 SHIM (0.1) DIFF.BRG. 12 SHIMS (0.35) DIFF.BRG. 12 SHIMS (0.4) DIFF.BRG. 12 SHIM (0.5) DIFF.BRG. 12 SHIMS (0.25) DIFF.BRG. 12 SHIMS (0.15) DIFF.BRG. 12 SHIM (0.2) DIFF.BRG. 12 SHIM (0.3) DIFF.BRG.

TA65 Star AMT 16 EXPLODED VIEW OF SHIFTER FORK

TA65 Star AMT 17 SR. NO. DESCRIPTION 01 SUB-ASSY TOP COVER (AMT) 02 COVER;AMT;TOP 03 SLEEVE BEARING 03 SLEEVE BEARING 04 CAP SCREW M8X20 IS2269-12.9 SS9400 05 STUD M8X35-8.8-TS17112 SS8451S2Y 06 SPRING SEAT 07 THRUST BEARING 07 THRUST BEARING 08 SUB ASSY. SPRING SEAT 09 CYL PIN 6m6X12 IS 2393 10 SUB ASSY INHIBITOR 11 INHIBITOR MOVABLE DOG 12 TORSION AND COMPRESSION INHIBITOR SPRING 13 SHAFT;SELECTOR & SHIFTING 14 INHIBITOR FIXED DOG 15 SPIRAL PIN 4 X 24 16 INTERLOCK & SHIFT FINGER ASSY 17 CROSS PIN;SHIFTER/SELECT FINGER 18 SELECTOR SHIFTER SHAFT ASSY 19 INTERFACE FINGER 20 SELECTION SPRING (ASSY. TOP COVER COMPLETE) 21 SPIRAL PIN (6X28) 21 SPIRAL PIN 6X28 IS8351-SS8400 22 SEALING WASHER 6X10 IS3175 CU 23 INHIBITOR LOCK SCREW 24 ASSY. TOP COVER COMPLETE (AMT) 25 HEX FL BOLT M8X45 TS17070 8.8 SS8451S2-Y SR. NO. DESCRIPTION 26 BRACKET 27 BRACKET ASSY;WIRING HARNESS MTG 28 DOMED CAP NUT (FOR CYL.HEAD COVER MTG.) 29 NYLOC NUT M8 IS7002-8-SS8451S2-Y 30 HEX FL BOLT M8X85 TS17130 8.8 SS8451S2-Y 31 HEX FL BOLT M8X70 TS17130 8.8 SS8451S2-Y 32 HEX FL BOLT M8X38 TS17070-8.8SS8451S2-Y 33 PRESSURE RELIEF VALVE (M/S SHRICHARAN) 34 WIRING HARNESS;AMT LINK 35 BRACKET ASSY TRANSAXLE 36 BRACKET;B-MOUNT TRANSAXLE 37 STUD 38 H/FL BOLT M10X40 TS1713010.9SS8451S2-YH 39 GEAR SHIFTER UNIT ASSY 39 GEAR SHIFTER HOUSING ASSY 40 GROMMET ASSY 41 GROMMET 42 PLATE 43 WASHER A8.4 IS5370 ST SS8451S2-Y 44 CAP SCREW M8X30 IS2269-12.9SS9400 45 HEX FL NUT AM6 TS17430-8SS8451S2-Y 46 TRANSMISSION INPUT SPEED SENSOR-MAGNETI MARELLI 46 OFFER-TRANSMISSION INPUT SPEED SENSOR

TA65 Star AMT 18 EXPLODED VIEW OF LAY SHAFT AND INPUT SHAFT: SR. NO. DESCRIPTION 01 SHIFTER SHAFT (5/R SPEED) 02 DOG (5/R SPEED) 03 ASSY DOWEL SLEEVE 04 SHIFTER FORK;5/R SPEED 05 DOG (3/4 SPEED) 06 FINGER;SWING LEVER RI 07 BALL 8 DIA GRADE-20 IS2898 08 SHIFTER SHAFT (3/4 SPEED) SR. NO. DESCRIPTION 09 SHIFTER FORK 3/4 10 SHIFTER SHAFT (1/2 SPEED) 11 SUB.ASSY SHIFTER SHAFT (5/REV) 12 INTEGRAL FORK ASSY. (1/2 SPEED) 13 SHIFTER SHAFT SUB ASSY;1/2 14 CIRCLIP E 12X1.3 IS3075 PT3 SS8400 15 SUB. ASSY SHIFTER SHAFT (3/4) 16 SPIRAL PIN

TA65 Star AMT 19 SR. NO. DESCRIPTION 01 LAYSHAFT (65/16) 02 CYLINDRICAL ROLLER BRG (L/S);FAG 02 CYLINDRICAL ROLLER BRG.(L/S);SKF 02 CYLINDRICAL ROLLER BEARING (L/S) (ABC) 02 CYLINDRICAL ROLLER BEARING (L/S);NRB 02 OFFER DRG.CYLD.ROLLER BRG.(L/S FRT.END) 02 CYLINDRICAL ROLLER BEARING (TEXSPIN)(ADAPTOR SHAFT 03 BUSH (LAYSHAFT) 04 CIRCLIP (LAYSHAFT) 04 CIRCLIP (LAYSHAFT) 04 CIRCLIP (LAYSHAFT) 04 CIRCLIP (LAYSHAFT) SR. NO. DESCRIPTION 05 ASSY TWIN CONE 1ST/2ND (DIVGIWARNER) 06 SYNCHROCONE OUTER (1st/2nd) BORG-WARNER 07 INTERMEDIATE CONE (1st/2nd) BORG-WARNER 08 INNER CONE (1ST/2ND) BORGWARNER 05 ASSY TWIN CONE 1ST/2ND 06 SYNCHRO CONE;OUTER;1ST/2ND 07 INTERMEDIATE CONE 1ST/2ND (INA) 08 INNER CONE 1ST/2ND WITH CARBON LINING 05 "OFFER" ASSY TWIN CONE 1ST/2ND 06 "OFFER DRG" SYNCHROCONE OUTER 1st/2nd 07 "OFFER DRG" INTERMEDIATE CONE 1ST/2ND

TA65 Star AMT 20 SR. NO. DESCRIPTION 08 "OFFER DRG" INNER CONE 1/2 (CARBON LNG) 05 TWIN CONE ASSY;1ST/2ND SPEED 06 SYNCHRO CONE;OUTER;1ST/2ND 07 INTERMEDIATE CONE;1ST/2ND SPEED 08 INNER CONE 1ST/2ND WITH CARBON LINING 09 ENGAGING GEAR 1ST/2ND (SINT SOFT VER.) 10 SLEEVE (1/2 SYNCHRO) 11 BALL 5.556DIA-GRADE 20 IS2898 12 SPRING (SYNCHRO) 13 CARRIER (1/2 SPEED) 13 CARRIER;1ST/2ND SPEED 14 REV.GEAR/SHIFTER SLEEVE 1ST/2ND SPEED 15 2ND GEAR LAYSHAFT (RATIO 1.95) 16 3RD GEAR LAYSHAFT (RATIO 1.27) 17 SYNCHRO CONE;3RD/4TH/5TH SPEED 18 ENGAGING GEAR 3RD/4TH SPEED 19 SHIFTER SLEEVE 3RD/4TH SPEED 20 CARRIER (3/4/5 SPEED) 20 CARRIER;3RD/4TH/5TH SPEED 21 SYNCHRO RING (4/5 SPEED); SPLINED 21 SYNCHRO RING (4TH/5TH SPEED) LASER WELD 22 PLATE (4TH/5TH SPEED GEAR) 23 4TH GEAR LAYSHAFT;SPLINED 23 4TH GEAR LAYSHAFT (0.95) LASER WELD VER.N 24 SPACER (L/S) 25 BALL BRG.WITH SNAP RING (L/S REAR);FAG 25 BALL BRG.WITH SNAP RING (L/S REAR) NRB 25 ASSY.BRG.WITH SNAP RING (L/S REAR END) 25 BALL BRG.WITH SNAP RING (L/S REAR);TISCON 26 LOCK PLATE (LAYSHAFT BRG.) 27 SPACER (REVERSE IDLER GEAR) 28 BUSH (5TH GEAR L/S) NRB SR. NO. DESCRIPTION 28 BUSH (5TH GEAR L/S) 29 NEEDLE CAGE (5TH GEAR L/S); NRB 29 "OFFER DRG"D/R NEEDLE CAGE(5TH GEAR L/S) 30 5TH GEAR LS (0.77) LASER WELD VERSION. 30 5TH GEAR LAYSHAFT (SPLINED VERSION) 31 ENGAGING GEAR 5TH SPEED 32 SHIFTER SLEEVE (5TH SPEED) 33 LOCK PLATE (5TH SPEED GEAR) 34 LOCK NUT (LAYSHAFT/INPUT SHAFT) 35 SOCKET HEAD CAP SCREW 36 BALL BRG.(I/S FRT.END) SKF 36 BALL BEARING (I/S FRONT END);TISCO 36 BALL BEARING;(FAG PRECISION BRGS.) 36 BALL BEARING ;(ABC) 36 "OFFER DRG" D.G.BALL BRG.(I/S FRONT END) 37 INPUT SHAFT (RATIO 3.64;1.95;1.27;0.95) 38 OFFER DRG.D.G BALL BRG.(I/S REAR END) 38 BALL BRG.WITH SNAP RING (I/S REAR) TISCON 38 BALL BRG.WITH SNAP RING (I/S REAR) NRB 38 BALL BRG. WITH SNAP RING (I/S REAR) FAG 39 5TH GEAR (INPUTSHAFT) 40 CONICAL WASHER 41 LOCK PLATE (INPUTSHAFT BRG.) 42 INPUT SHAFT ASSY;5TH SPEED(STD) 43 REVERSE IDLER GEAR (FOR SEDAN) 43 REVERSE IDLER GEAR 44 "OFFER PART" NEEDLE BUSH (SKEWED) 44 NEEDLE BUSH (SKEWED) INA 44 NEEDLE BUSH (NRB) SKEWED 45 SYNCHRO RING (5TH) LASER WELD VERSION 45 SYNCHRO RING (4TH/ 5TH SPEED) 46 1ST GEAR LAYSHAFT (RATIO 3.64)

TA65 Star AMT 21 10. REMOVAL OF TRANSAXLE FROM VEHICLE: Position the vehicle properly on the two post lift 1. Remove Battery terminal as shown. 2. Disconnect all electrical connection & take out Battery. 3. Remove Mtg.screws & take out Battery Tray by loosening Fuse Box. 4. Remove Translink cable or AMT coupler as shown below 5. Remove Battery cable from Bracket. 6. Position the vehicle properly on the two post lift and remove Tyres as shown 7. Remove Tie Rod on LH & RH side. 8. Remove Suspension Mtg. vertical link (antiroll bar) from Strut on LH & RH side.

TA65 Star AMT 22 9. Remove ball joint (steering rack) from steering knuckle from RH & LH sides 10. Remove stub axle ball joint Mtg. & Remove Lower Control Arm (LCA). 11. Drain the Transaxle oil from Drain plug as shown below 12. Swing out both drive shafts from transaxle and place it suitably alongside. Do not pull drive shaft excessively as the plunge joint will come out of housing and damage the boot Pry. Plunge joint housing for taking out joint out of splines. Do not place the CV drive shaft on rough / uncleaned surfaces. This might damage the drive shaft boot. 13. Disconnect Transmission arthing cable from Gear Box. 14. Lower the car & support the Engine from Bottom side. 15. Remove B-Mount Nut & Loosen B Mounting stud as shown 16. Remove starter motor mounting Bolt.

TA65 Star AMT 23 17. Remove Housing mounting bolts on Engine from top side. 18. Uplift the car on post & give support to Engine using lifting Device. 19. Remove Housing mounting bolts on Engine from Bottom side. 20. Remove Electrical connection of Speed Sensor & to AMT Kit. 21. Disconnect C mountings as shown 22. Lastly Remove Gear Box Rounding Bolt 23. Lower Gear Box with AMT KIT. 24. Remove Nyloc nut on AMT & take out AMT Kit from Gear Box. 25. Remove the cooling module of the vehicle (Refer Remove and Re-fitment of cooling module in engine). 26. Remove fuel line supporting bracket from clutch housing. INSTALLATION OF TRANSAXLE Follow the Reverse Procedure as given above

TA65 Star AMT 24 11. TRANSAXLE TA65 STAR AMT (ON BENCH) DISASSEMBLY: 1. Ensure that oil is drained completely from the transaxle before mounting on the work stand. 2. Remove domed cap nut & Nyloc nut take out Brackets as shown 3. Remove all electrical connection from AMT Kit. 4. Remove clutch interface as shown 5. Remove all mounting Bolts & Nyloc nut from top & bottom side from AMT kit as shown 6. Lastly take out AMT Kit from Transaxle. 7. Fix the mounting plate (2702 5890 2610) on work stand 2573 5890 3701 (19a) by using hex bolt in 3 holes of 14mm dia. on the mounting plate. 8. Mount transaxle face on mounting plate and fix it by three hex bolts of M10 size. 9. Remove spiral key from AMT & take out interface finger as shown 10.Remove AMT top cover assembly.

TA65 Star AMT 25 11. Remove hex flanged screw holding release lever on to release yoke and take out release lever from release yoke. 12. Turn the table by 900. 13. Lock input shaft using adapter 2702 5890 2611. 14. Turn back the table by 900. 15. Remove rear cover. 16. Remove 5th gear spiral pin, on shifter fork. 17. Engage any gear using selector/shifter mechanism. 18. Unstake and unscrew the locknut on lay shaft. 19.

TA65 Star AMT 26 20. Remove engaging gear (5th speed) along with sleeve and fork taking care that carrier assembly does not slip off. 21. Remove the gear and engaging gear along with the synchrocone. Do not allow the carrier assembly to slip off the lay shaft. 22. Remove needle bush 1 and bearing 2. 23. Remove spacer (lay shaft). 24. 25. Remove the conical washer.

TA65 Star AMT 27 26. Remove the 5th gear (input shaft). 27. Remove lock plate (lay shaft bearing) from housing rear half by unscrewing T40 torx head screws. NOTE: Use new torx head screws during reassembly 28. Remove lock plate input shaft bearing from housing (rear half) by unscrewing the screws. 29. Remove the hex flanged bolts & filler plug on housing. 30. Remove B-mount Bracket as shown 31. Remove the hex flanged bolts on the housing.

TA65 Star AMT 28 32. Rotate the transaxle upside down. Remove the hex flange bolts provided at clutch housing. 33. Remove clutch speed sensor mounting bracket. 34. Remove hex screw & take out clutch speed sensor. 35. Remove vehicle speed sensor as shown 36. Remove the gear box housing (rear half) by gently tapping with a mallet. 37. Remove reverse idler shaft, & Reverse lower bracket Assembly.

TA65 Star AMT 29 38. Remove reverse idler gear assembly. 39. Remove the adaptor part no. 2702 5890 2611 for locking input shaft. Tap the input shaft gently from the spline end also top the lay shaft. 40. Pry out the input shaft, and lay shaft along with shifter shaft assembly from the clutch housing. 41. Remove the differential assembly along with the oil seal and taper roller bearing from the housing front. 42. Remove the input shaft cover by removing M6 * Mounting Bolts. 43. Try out the oil seal from the cover (if damaged) and replace it with new one. 44. Remove the plastic bushes at both ends of clutch release fork and remove the clutch release shaft from inside. 45. Remove oil seals of drive shaft from differential housing. Replace it with a new one while assembling. 46. Remove bearing outer races of differential side bearing along with shims. Ensure that outer races are not interchanged. NOTE: SHIMS SHOULD NOT BE REUSED. NOTE: 1. Apply anabond 112 on threads of all fasteners 2. Apply RTV silicon liquid gasket anabond 676 on housing interface. 3. The chips collected by magnetic drain plug, are to be removed at the time of every oil change. 4. Keep inner and outer races of taper roller bearing in sets. 5. Use sealing anaerobic compound for all oil seals outer diameter. 6. For oil seals of input drive shaft and bellows use anabond 112.

TA65 Star AMT 30 12. SUB ASSEMBLIES: INPUT SHAFT SUB ASSEMBLY: 1. Remove deep groove ball bearing (rear) by using holder part no. 2702 5890 2606 with puller part no. 2654 5890 3508. 2. Remove deep groove ball bearing (front) by using puller part no. 2657 5890 2801. INPUT SHAFT ASSEMBLY: 1.Place and fit deep groove ball bearing (rear) on input shaft using drift part no. 2651 5890 3308 with taper groove for Lock Plate in upward direction). DISASSEMBLY OF LAY SHAFT: 1. Remove deep groove ball bearing (rear) Remove Deep groove Ball bearing from lay shaft by using holder 2702 5890 2607 with puller 2654 5890 3508.

TA65 Star AMT 31 2. Remove spacer. 3. Remove sub-assembly 4th gear (lay shaft) along with the plate. 4. Remove Synchro pack assembly (3/4 speed) CAREFULLY so that springs, carriers and balls do not jump out. Synchro pack -Shifter sleeve, engaging gear, synchro cone, spring, ball, carrier (sleeve in case of 1st gear). 5.Pry out circlip from lay shaft. 6.Remove 3rd gear lay shaft. 7.Pry out circlip from lay shaft.

TA65 Star AMT 32 8. Remove 2nd gear from lay shaft. 9. Remove the double synchro pack that sits on the second gear 9a. Remove the engaging gear pack (1/2 speed) CAREFULLY so that springs, carriers and balls do not jump out. 9b. Remove the double synchro pack that sits, on the first gear. 10. Pry out circlip from lay shaft. 11. Remove 1st gear lay shaft. 12. Pry out circlip from lay shaft. 13. Place the lay shaft upside down and remove cylindrical roller bearing using drift Part No. 2702 5890 2605.

TA65 Star AMT 33 IDNETIFICATION OF COMPONENTS 1. ENGAGING GEARS: 1. 5th engaging gear is having smaller dia inner spline for fitment on lay shaft. 5th Engaging Gear 2. 3rd and 4th engaging gear is similar in size with 5th engaging gear but having bigger inner splines to fit on lay shaft. 3rd & 4th Engaging Gear 3. 1st and 2nd engaging gear is having inner spline dia similar to 3rd/4th engaging gear but outer dia is bigger to engage with 1st/2nd shifter sleeve. 1st & 2nd Engaging Gear 2. SHIFTER SHAFT SUB ASSEMBLY: Gently hammer the double dowel pins of the shifter fork after placing in vice to remove the shifter fork from shifter shaft as marked in

TA65 Star AMT 34 3. SHIFTER FORKS: 1. 5th gear shifter fork is longer than 3, 4th gear shifter forkend has dowel hole in the center of the boss. 2. 3rd and 4th gear fork has shorter ribs. 3. 1st and 2nd gear shifter fork has the smaller two ribs with shifter finger integrated to fork itself. 4. SYNCHROCONE: 1. 5th/4th/3rd synchrocones are having smaller inner dia and are identical. 2. Each 1st and 2nd synchrocones has three pieces outer cone (sits on engaging gear) intermediate part and inner cone (sits on gear). 5. SHIFTER SHAFTS 1. 1st and 2nd shift has only one hole for shifter fork fitment. 2. 3rd and 4th shifter has two holes for dowel pin with notch at one end for inter lock ball. 3. 5th/Rev. shifter shaft is the longest of all. 4. SHIFTER SLEEVE: 1. 3rd and 4th shifter sleeve. 2. 5thsleeve is having d ach chamfer on dog teeth only on one side. 3. 1st and 2nd shifter sleeve is integral with reverse gear.

TA65 Star AMT 35 SUB ASSEMBLIES: 1. 5th SYNCHROPACK ASSEMBLY: 1. Place needle roller bearing and bush in 5th gear. 2. Assemble the carrier 3/4/5 spring, balls engaging gear and shifter sleeve. NOTE: The engaging gear can be put in either way. 3. Place synchrocone on 5th gear lay shaft. 4. Place Synchropack assembly with shifter sleeve on 5th gear. 5. Ensure that slot or fork pad on shifter sleeve be in downward position. 2. 3rd / 4th SYNCHROPACK ASSEMBLY: 1. Place the engaging gear such that the groove for circlip is downwards. 2. Place the shifter sleeve on engaging gear 3rd/ 4th such that the smaller groove is upwards and assemble the carriers, springs and balls. 3. 1st / 2nd SYNCHROPACK ASSEMBLY: 1. Place inner cone. 2. Place the intermediate cone in such a way that the lugs sit exactly in the slots of 1st gear

TA65 Star AMT 36 3. Now place the outer synchro cone. 4. Place the engaging gear in such a way that the inner cone lugs sit properly inside the grooves provided in the engaging gear. 5. Place the engaging gear 1st and 2nd such that the reverse gear tooth over it is towards the 1st gear. 6. Place the 2nd gear and assemble the twin cones as shown and place it over the engaging gear as shown in below figures.

TA65 Star AMT 37 LAY SHAFT ASSEMBLY: 1. Press cylinder roller bearing on lay shaft by using drift part no. 2702 5809 2603. 2. Fit the circlip. It should snugly fit. NOTE: Circlips are available in different thicknesses. 2.25mm,2.3mm,2.35mm,2.4mm. 3. Place first gear (lay shaft) on lay shaft by keeping dog teeth upward. 4. Install preselected circlip (Circlip thickness should be so selected that there is no axial play of gear). 5. Place the double synchro pack fitted over the first gear. 6. Place engaging gear (1/2 speed) with circlip races downward and with slot on engaging gear on corresponding lug on synchrocone 7. Place springs (3 nos.) plungers (3nos.) into the hole in engaging gear (1/2 speed). 8. Place sleeve carrier and steel ball on it and slide reverse gear/shifter sleeve (1/2 speed) on it with fork slot in upward position. 9. Place the Rev gear/shifter sleeve on the layshaft.

TA65 Star AMT 38 10.Place the double synchrocone pack for Second gear on the engaging gear. 11. Place 2nd gear with its dog teeth downward. 12. Install preselected thickness circlip on it. 13. Place 3rd gear layshaft with its dog teeth upwards. 14.Fit preselected circlip. 15.

TA65 Star AMT 39 16. Place engaging gear with circlip recess downward and with slot on engaging gear on corresponding lug on synchrocone. Place springs (3 nos.) carrier (3/4/5) (3 nos.) and steel balls (3 nos.) and slide shifter sleeve (3/4/5 speed) on it. Ensure that the slot for fork pad on shifter sleeve (3/4/5) will be in downward position. 17. Place synchrocone (4th gear) and locate its lug into slots of engaging gear. 18. Place 4th gear. 19. Place the spacer. 20. Press deep groove ball bearing with taper groove for lock plate side upwards on lay shaft using drift part no. 2641 5890 2601. 21. Press the cap on Lay shaft oil hole bore (below the final drive pinion).

TA65 Star AMT 40 DIFFERENTIAL ASSEMBLIES: 1. DISASSEMBLY: 1. Remove taper roller bearings by using puller part no. 2702 5890 2604, and rest pad part no. 2702 5890 2612N. 2. Remove sensing wheel using by puller part no. 2651 5890 3506 and rest pad part no. 2702 58902612N. 3. Remove two (1.5 Thick) circlips locking the spider. NOTE: DO NOT REUSE THE 1.5 THICK CIRCLIPS. 4. Push out spider from differential housing. 5. Rotate bevel pinions by 900 and remove the side bevel gears. 6. Remove bevel pinions with washers. 7. Hold fixtures for gear on differential assembly part no. 2702 5890 2609 in soft jaw vice. 8. Mount differential housing on fixture part no. 2702 5890 2609 and lock it.

TA65 Star AMT 41 9. Unscrew and remove the collared bolts (10 Nos.). 2. ASSEMBLY: 1. Hold fixture for gear on differential casing on soft jaw vice. 2. Mount differential housing on fixture part no. 2702 5890 2609 and lock it. 3. Place gear final drive on differential housing. Tighten the collared bolts (10 nos.) to specified torque of 8 to 9 mkg. 4. Place both the bevel gear on the differential housing with spacer. 5. Place another set of idler bevel gear on the already lifted bevel and rotate by 90° so as to align the bevel to spider shaft hole. 6. Push the spider into the hole. 7. Check the free play of differential gears. It should be 0-0.1 mm. 8. If the value of play is not within specifications, then try with different thickness washer. 9. Assemble the two 15x1.5 thick circlips into the groove near the ends of spider. To check backlash, hold the two different pinions and one side gear and check free play or remaining side gear teeth flank as shown in 10. Fix sensing wheel with recess inside using drift part No. 2654 5890 3507. 11. Press taper roller bearings using drift part no. 2702 5890 2608 on either side of differential housing.

TA65 Star AMT 42 12. ASSEMBLIES OF TRANSAXLE: 1. Fit clutch release fork shaft. Fit plastic bushes. Fit lever on clutch release shaft and lock it by grooved pin. 2. Differential bearing preload adjustment procedure. mating surface of transaxle front half and the outer differential bearing seat) say 103.7mm between mating surface of transaxle rear half and the inner differential bearing seat) say 19mm in housing for bore 65.088 mm dia. Place outer races on both differential side bearings and measure distance between outer surfaces of these outer races Select shim thickness = (A+B) - C to (A+B) - C+ 0.05 and install the shims against front half taper roller bearing outer race. 3. Fix the outer race of differential bearing in the housing (front half) by using drift part no. 2654 5890 3507. 4. Remove sensing wheel using by puller part no. 2651 5890 3506 and rest pad part no. 2702 58902612N. 5. Place the assembly differential in front half housing.

TA65 Star AMT 43 6. Fix the shifter shaft to the shifter fork of first and Second gear and lock it by dowel pin. 7. Insert the third and fourth, fifth and reverse shifter Shaft after locking by interlock balls and with Shifter dogs fitted. 8. Insert the third and fourth, fifth and reverse shifter Shaft after locking by interlock balls and with Shifter dogs fitted. 9. Place the 3/4 shifter fork on the 3/4 shifter Shaft in such a way that it sits properly on the 3/4 shifter dog as shown in figure (and lock it by dowel pin. 10. Place the lay shaft assembly and input shaft assembly together along with shifter rail assembly. 11. Fix the reverse gear assembly on the rear housing half into the seat of reverse idler gear. Also fix the reverse lever bracket.

TA65 Star AMT 44 12. Ensure that all the spiral pins are pressed properly. 13. Apply liquid gasket (Anabond 90 or 3 bond 12S00) with proper bead size on front half / interface. 14. Assemble the housing (rear half) on lay shaft input shaft and shifter shaft and tap it gently and uniformly so that it gets located on lay shaft and input shaft bearing. 15. Fix the housing (rear half) and tighten the flanged mounting bolts to specified torque. 16. Place lock plates of lay shaft bearing and input shaft bearing and fix them by allen screws. Tap the shaft in either direction if required. 17. Place spacer on lay shaft. 18. Put input shaft 5th gear on input shaft. NOTE: Ensure ground face (5th gear I/S) towards the bearing face. 19. Put conical washer and lock nut on input shaft. 20. Place 5th gear assembly (lay shaft) with bush and needle cage and synchro pack (5/R) along with shifter fork (5th gear) on shifter sleeve. Locate shaft hole on shifter fork to shifter shaft. 21. Lock the shifter fork on shifter shaft by spiral pin. 22. Place lock plate on lay shaft 5th gear assembly 23. Fix lock nut on lay shaft. 24. Lock the input shaft from below. Engage any one of the gears. 25. Tighten the lock nuts on both lay shaft and input shaft by giving torque of 12.3-16.7 mkg. 26. Stake the collar of both lock nuts on lay haft and input shaft. 27. Check the correct positioning of shifter shaft by moving gear shifter shaft assembly in neutral. Assemble the speedo sensor back on the rear housing. 28. Place assembly rear cover with liquid gasket on housing (rear half) and fix it by assembly hex screws (3Nos.). 29. Tighten the screws to specified torque. NOTE: Clean the front half and rear half interfaces/ so that no cured and dried liquid gasket remained are left on the machined surfaces. 30. Unlock the input shaft from below. 31. Fix reverse light switch on housing (rear half), Fix magnetic drain and filter plugs with new washers. 32. Fix the C-mount bracket on the gear box front housing. 33. Fix the B-mount bracket in the correct orientation. 34. Unscrew 3 mounting bolts (M8) and dismount the transaxle assembly from adaptor plate on work sand.

CLUTCH CLUTCH (For TA-65 Star AMT)

CLUTCH INTRODUCTION: CLUTCH The clutch is a single disc dry friction type with a diameter of 200 mm. It is of diaphragm type and is mechanically actuated by a cable connecting clutch pedal and the clutch release lever. No clutch pedal free play adjustment is required although clutch pedal height from floor has to be adjusted as the clutch lining wears. The clutch pedal height from the floor keeps on increasing as the clutch lining wears.

CLUTCH CONTENTS 1. GENERAL INFORMATION ....................................................................................................................... 1 2 TEHCNICAL SPECIFCICATIONS & TIGHTENING TORQUES............................................................... 1 3. DIAGNOSIS ............................................................................................................................................... 4 4. CLUTCH..................................................................................................................................................... 6 A. THEORY OF DIAPHRAGM SPRING CLUTCH .................................................................................... 6 B. CONSTRUCTIONAL DETAILS ............................................................................................................. 7 C. FACTOR AFFECTING CLUTCH WEAR............................................................................................... 9 D. REMOVAL OF CLUTCH FROM THE CAR........................................................................................... 9 E. INSTALLATION OF CLUTCH ON THE CAR ........................................................................................ 9 5. MAINTENANCE, ADJUSTMENT AND TESTS TRANSAXLE ............................................................... 10

CLUTCH 1 1. CLUTCH DESCRIPTION Clutch is a mechanism interposed between engine and the Transaxle which enables engine power as well as torque of the engine to be transmitted to the transaxle through friction drive. When clutch pedal is depressed the clutch is disengaged and therefore motion and power flow from engine to Transaxle and hence to road wheels is disconnected. It is a single disc dry friction type clutch having 200 mm dia. clutch disc. Clutch pressure plate assembly is diaphragm spring type. Clutch actuation is through mechanical linkages (cable). 2. TECHNICAL SPECIFICATIONS: TYPE PETROL Cover Assembly Single disc dry friction Diaphragm spring type Disc Assembly Non-asbestos LUK B8080 facings Release bearing Assembly Self-Centering Type CLUTCH DISC 1. Outer Diameter 200 mm 2. Inside Diameter 134 mm 3. Thickness of Clutch disc with new lining under 3850 N load 7 ± 0.2 mm 4. Max. Permissible imbalance of clutch disc 30 gm-cm 5. Cushioning of Clutch disc 0.65 to 0.9 mm 6. Total Friction Area (Both sides) 346 sq. cm TIGHTENING TORQUES Clutch Housing to Cylinder block 4.6 mkg. Clutch Pressure plate mounting bolts 2.4 mkg.

CLUTCH 2 CLUTCH DISC

CLUTCH 3 CLUTCH PRESSURE PLATE PETROL 1. Max finger height of Pressure plate from clutch mounting face 18.7 ± 1mm 2. Max permissible imbalance of clutch cover assembly. 200 gm-mm 3. Max finger run out 0.8 at 34 mm dia 4. Clamp load (Minimum on unloading curve) 3850 N 5. Max. release load (New gauge plate) 1200 N 6. Release travel 8 + 1mm 7. Max. Wear travel 6.14 mm 8. Min. Pressure plate lift for release travel of 8 mm 1.4 mm

CLUTCH 4 3. DIAGNOSIS OF CLUTCH: IN THE VEHICLE THE COMPONENT CAUSES REMEDY 1. New Clutch: Difficulty in changing gear Difficulty in changing gear, following replacement of clutch shaft. Burrs thrown up around splines causing stiff movement on shaft. Due to poor alignment of the gearbox on reassembly. The driven plate was improperly aligned. Aggressive location of shaft into hub. Care with the centering of driven plate; use an appropriate clutch aligning tool. Do not force the gearbox but rotate the flywheel or gearbox shaft to line up input with splines. 2. Loss of Drive: With recently fitted clutch Loss of drive and loud clatter, only covered a few hundred kilometers. The centre hub of the driven plate has ripped out and possibly one or more of the springs have been pushed out. The weight of the gearbox has been hung on the centre plate. This has distorted the driven plate resulting in failure within a short period of use. Very aggressive clutch r when towing a heavily laden trailer. Ensure that the gearbox shaft and gearbox are not hung on the clutch driver plate by using a pit jack or trolley jack to support the gearbox on reassembly. 3. Slipping Clutch Clutch slip. The control system is in good condition and correctly adjusted. The clutch friction material is contaminated with oil. There is an oil leak from the engine or gearbox. Carefully check the engine and gearbox oil seals. Replace seals if oil is present in bell housing. 4. Juddering During Pulling Away Clutch judder on initial take up of torque. Oil or grease found on the middle of clutch to driven plate. Excess grease applied on input shaft splines. Only use the correct amount and correct type of grease. 5. Juddering During Pulling Away Loss of Drive The friction material has come off from both sides (centrifuged). The facing has centrifuged. The shattered linings are lodged into cover assembly and loose in the bell housing. Some parts of the driven plate could be broken. Drive error e.g. accidentally changing from 5th to 2nd gear at 85 miles per hour.

CLUTCH 5 IN THE VEHICLE THE COMPONENT CAUSES REMEDY 6. Vibrations through the Pedal When Starting to De-clutch Pedal vibration when starting to De-clutch. The fingers of diaphragm are out of line and show sign of damage. The gearbox input shaft has struck the fingers of the diaphragm on fitting. Carefully guide in the gearbox to avoid any knocks on fitting. 7. Metallic Sound with Pedal Fully Depressed Metallic sounding noise affected by engine speed with pedal fully depressed. Signs of rubbing on the diaphragm fingers, in the area of contact with the release bearing. Incorrect clutch adjustment excess travel. Systematically check the condition of cable linkage and automatic adjuster. Always refer to vehicle workshop manual for correct adjustment. 8. Noisy Clutch The clutch is noisy and the pedal cab be slack. A location lug on the release bearing has broken. A lug has broken. Another fault in the mechanical operation of the lug to break. For example, the fork is out of shape or wrongly positioned at the time of assembly. Check the fork and guide sleeve and replace if signs wear are present. Ensure components are lubricated. Carefully check at the clutch cable. 9. Permanent Loud Noise Permanent loud noise. The levers are badly damaged and the release bearing has seized. Incorrect clutch adjustment causing bearing failure. Regularly check the clutch adjustment. Always refer to manual for correct method of clutch adjustment. 10. Slipping and Juddering The clutch slips and eventually judders. The pressure plate burn marks. Driver resting foot on pedals. Incorrect clutch adjustment. Regularly check the clutch adjustment. Always refer to manual for correct method of clutch adjustment Educate the driver. 11. Juddering after changing the Clutch The clutch judders. Circular grooves can be seen on the friction material on the flywheel side. The clutch has been replaced when the flywheel has been previously scored. Systematically check the condition of the flywheel. Skim flywheel if necessary.

CLUTCH 6 4. CLUTCH A. THEORY OF DIAPHRAGM SPRING CLUTCH When engaged, the clutch allows the engine driveline to rotate together as one solid member When disengaged, the engine from the driveline allowing it to remain running while the vehicle is stopped. The clutch can be used to interrupt and reconnect the flow of engine power to allow the changing of gears.

CLUTCH 7 B. CONSTRUCTIONAL DETAILS

CLUTCH 8 SR. NO. DESCRIPTION 1 Hex Fl Bolt M10X55 TS17130-8.8 SS8451-8C 2 Hex Fl Bolt M10X45 TS17130-8.8-SS8451S2-Y 3 Back Cover with Damping Pad 4 Clutch Disc Assembly 5 Clutch Cover Assy 6 Hex. Flange Screw 7 Sleeve 8 Hex Fl Bolt M10X65 TS17130-10.9-SS8451-8CH 9 Rear Cover 10 Hex Fl Bolt M8X25 TS17130-8.8-SS8451-8C 11 Bush, Lower 12 Clutch Release Yoke 13 Bush, Upper 14 Clutch Release Shaft 15 Hex Fl Bolt M8X45 TS17130-8.8-SS8451S2-Y 16 Hex Nut AM8 TS17430-8-SS8451-8C 17 Clutch Release Lever 18 AMT Kit Assy. With W/H

CLUTCH 9 C. FACTORS AFFECTING CLUTCH WEAR The clutch is designed to give maximum life under most severe conditions when handled carefully. However, while in operation, clutch lining is subjected to wear. Apart from this the extent of wear also depends on following. Automatic transmissions use pressure to apply and release clutches, or essentially shift gears. This pressure is affected by a number of variables, but the baseline numbers are determined in large part by the fluid and its relative condition, which is affected by heat. Hot, older fluid can decrease (or increase) the pressures within the transmission beyond engineered tolerances. When this happens components begin to fail and soon the driver is left with an expensive repair bill. DRIVING Following driving conditions will affect the performance of the clutch. D. REMOVAL OF CLUTCH FROM THE CAR: 1. Position and Lift the car using two post lift. 2. Disconnect electrical connections from AMT, clutch position sensor. 3. Disconnect and remove transaxle along with clutch housing from engine (for procedure refer transaxle group). 4. Loosen the clutch lever interface. 5. Remove clutch release bearing with sleeve 6. Support clutch pressure plate and clutch disc with mandrel & remove. NOTE: 1. It is recommended to replace a defective disc having any of the above mentioned defects with a new genuine clutch disc. We do not recommend removal and replacing of clutch facing. 2. We do not recommend overhauling of the clutch pressure plate assembly. However, before re-fitment, the assembly should be checked for specifications and should conform to the data of clutch pressure plate assembly given on page 3. 3. Use correct clutch discs for the 1.22 NG NA versions Identification. 4. Use Disc and Pressure plate of the same make. Ensure that the clutch facing material is not contaminated with oil or grease as this shall result in clutch slipping. E. INSTALLATION OF CLUTCH ON THE CAR: Carryout the clutch removal steps in appropriate sequence for its fitment. However, following care must be taken during installation. Clean friction face of flywheel and check for cracks, scoring, burn marks or unevenness. If necessary, machine flywheel friction face just to clear the defect. Before fitment of clutch on the flywheel remove 3 protective clamps from pressure plate assembly. For removal of 3 clamps, press Diaphragm fingers of pressure plate assy. till the clamps becomes loose & take it out. Lightly apply Dow corning P40 grease on the disc splines. Install disc and pressure plate assembly. Press the aligning mandrel through the pressure plate assembly and clutch disc and centralize clutch disc on flywheel by locating the mandrel at the flywheel end. NOTE: Do not mix clutch mounting bolts with other fasteners. Do not use longer or shorter screws. Longer screws may not tighten the clutch at all. Shorter screws will not provide enough threads to achieve desired tightening. While tightening the clutch mounting screws check aligning mandrel for continuous free sliding to ensure concentric installation of clutch disc which will avoid trouble during the installation of the transaxle

CLUTCH 10 5. MAINTENANCE, ADJUSTMENT AND TESTS INSPECTION OF COMPONENTS i. Check clutch disc hub splines for damage and wear. ii. Check torsion damper mechanism springs for distortion, damage etc. For this purpose, hold drive shaft in vice. Insert clutch disc and slide it as far back as possible. Rotate disc by hand. Rattling noise and excessive play indicates damaged torsional damping mechanism and such disc must be replaced. iii. Check disc facing for wear, cracks, contact pattern, burning marks and oil contamination. Facings with any of the above defects or worn out beyond permissible limits must be replaced. iv. Check the correct position of clutch pedal lever, which should be In-line with the brake pedal lever, (During every service check the clutch pedal lever is ln-line with brake pedal, if not set in-line with the brake pedal lever). 1. CLUTCH SLIPPAGE TEST Clutch slippage can be confirmed by any of the following two methods: i. Drive the car in 1st or 2nd gear at maximum speed corresponding to that gear. Keeping the accelerator pedal pressed with your right foot, apply brake gradually with your left foot If the engine stalls, it means that clutch does not slip. ii. Drive loaded car in 3rd gear on level ground and let the speed drop down to approximately 15 kmph. Now press the accelerator pedal fully. With slipping clutch, the car speed will not pick up and also clutch burning smell will be noticed. If this does not occur and the car picks up speed, it indicates that clutch does not slip.

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