Clutch Industries TBC91 Standard Replacement Clutch Kit Instruction Manual
- June 3, 2024
- Clutch Industries
Table of Contents
TBC91 Standard Replacement Clutch Kit
Instruction Manual
CSC Fitting Practice
To avoid premature failure (usually leakage) from the CSC, some basic
instructions must be followed whilst handling / fitting a new Concentric Slave
Cylinder.
Handling of new product
On removing the CSC from the box, do not compress the cylinder by hand to
replicate the bearing movement. Some CSCs are pre-charged with oil and
manually compressing the CSC can cause damage to the internal hydraulic seal
by introducing air into the CSC. Alternatively, some CSCs may not be pre-
charged with oil, and manually compressing the CSC will cause the same damage
by introducing air into the CSC.
By compressing the cylinder in this way, the increased air pressure can cause
the damage illustrated in the image. Further damage can occur to the internal
seals due to excessive friction on the return stroke when manually depressing
the CSC.
CSC Fitting Practice
Fitting environment
The area in which the CSC is positioned needs to be totally clean & free of
debris. It must locate cleanly and squarely onto the gearbox case, and any
rubber face seal or sealant is only used if the vehicle manufacturer’s
instructions recommend it. If the CSC is not seated correctly, the back face
can push out as below, which will cause it to leak and fail and is not covered
by warranty.
The CSC has not seated squarely, and hydraulic pressure has forced the back plate out of position.| New CSC – no damage to the back face plate
Fitting
Gently slide the CSC over the gearbox input shaft and slightly rotate it to
ensure the correct location on the gearbox case. Ensure the mounting surface
is clean and free from any debris. No sealant should be used on the mounting
surface. Torque down the mounting bolts evenly to the manufacturer’s torque
specification.
Hydraulic Connections
There are two types of connectors:
- Traditional screw in
- Quick clip connector which is more common.
With the traditional type, tighten the screw to the manufacturer’s
specification.
The quick clip connecter can be released by either pulling or pushing the
retaining clip, dependent upon the type.
Bleeding (Purging) the system
Before attempting to bleed/purge or operate the clutch, ensure that the
gearbox is fully located in the fitting position. Tighten a few securing bolts
to prevent any movement. This will avoid the unit from being over-stroked
causing damage to the chamber seal. Flush the hydraulic system to ensure all
contaminants and old sediment is removed from the system. Failure to flush the
system may contaminate the new CSC and cause premature failure of the CSC
which is not covered by the warranty. Bleed the system as per the vehicle’s
manufacturer’s instructions. Always use the correct hydraulic fluid as
specified by the vehicle’s manufacturer. Only use a pressure bleeding device
if recommended by the vehicle manufacturer.
PLEASE NOTE: Clutch Industries does not recommend the use of power
bleeding systems, as some systems run high air pressure. This can invert or
roll the internal seal resulting in immediate fluid loss.
Troubleshooting
Unable to select gears and no pedal (due to CSC failure). (See Image 1) The distortion to the retaining ring is a result of the bearing exceeding its maximum travel. The distorted retainer indicates that the bearing has been forced against the ring during the bleeding process. (See Image 2&3) This also damages the piston internal seal resulting in the loss of fluid past the seal. Over-stroking during the bleeding process is the result of the clutch pedal being pumped rapidly, which doesn’t allow the cylinder to return to rest before the next pump stroke.
The Solution
To avoid the cylinder being over-stroked, the pedal should be depressed and
then released slowly to allow the cylinder to return to rest before the pedal
is depressed again. In some cases, the bleed nipple/pipe may need to be locked
off after every downward stroke of the pedal, until some pressure in the
system is achieved. This process may need to be conducted numerous times
before some pressure is felt in the pedal. This is a common action required
when bleeding the system, as an airlock can occur within the clutch master
cylinder.
Freecall 1300 369 787
E: sales@clutchindustries.com.au
www.clutchindustries.com.au
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