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WHY DOES A CLUTCH FRICTION PLATE FLY APART?
A clutch plate is designed to withstand the normal stresses and pressures of engaging and disengaging the clutch to transmit power from the engine to the transmission. Under certain circumstances, a clutch plate can fail or “explode”, known as centrifugal disintegration.
Essentially, the clutch plate has been subjected to a centrifugal force beyond its operational rotational speed limit (rotated/spun too fast). The operational rotational speed limit before centrifugal disintegration is subject to the state and condition of the clutch plate. The operational speed limit becomes significantly reduced through age, environment and product deformation from incorrect use, maintenance and or installation.
Here are some common reasons why centrifugal disintegration might occur:
CLUTCH PLATE OVERSPEED:
A clutch friction plate can reach extreme rotational speeds where the vehicles engine sees RPM beyond the vehicles rated red line (RPM limit), or where the vehicle speed is able drive the transmission input shaft RPM to extreme speeds, such as a downshift to the wrong gear in relation to the vehicle speed, or allowing a vehicle in a low range gear cost down a decline with the clutch pedal depressed, as some common examples.
DAMAGED CLUTCH PLATE:
There are a large number of ways that a clutch friction plate can be damaged. Here are some of the more common causes of damage to a clutch disc:
a) Incorrect Application: Using a vehicle in a way that has higher demands than general use, that regularly exceed vehicle design, such as extreme loads, towing, hill climbs as some examples.
b) Overheating: Excessive heat can weaken the materials used in the clutch plate, causing it to fail. This can happen if the clutch is slipped excessively.
Some common reasons for why slippage might happen:
1) A problem with the clutch hydraulic system that prevents proper engagement and disengagement.
2) Excessive wear of the friction plate. When the friction material becomes too thin it can lose its ability to grip the flywheel and pressure plate.
3) Contamination of the friction plate. If the friction plate comes in contact with oil (a leak from the engine or gearbox for example), or other contaminants, it becomes slippery and unable to grip on the contact surfaces.
4) The flywheel has not been ground smooth and or the correct profile has not been restored. High and low spots develop in a flywheels surface during use. Without restoration of a smooth and true surface, the contact of the friction plate can be significantly reduced, and the friction plate is unable to grip correctly. Failure to restore the correct flywheel profile results in incorrect clutch and flywheel clearances.
5) Engine torque exceeds the operating limit of the clutch.
6) Aggressive driving generates extreme heat, causing the friction material to out-gas. This creates an air gap, reducing grip and inducing further slippage, similar to an air hockey table.
This is not intended to be an extensive nor exhaustive list of slippage causes.
c) Excessive Force or Abuse: Aggressive driving habits, such as aggressive clutch engagement or dropping the clutch at high RPMs, can put excessive stress on the clutch plate and lead to failure.
d) Incorrect installation: Incorrect installation of the clutch plate can cause improper engagement, resulting in premature wear and potential failure due to distortion, warpage, and imbalance weakening the structure.
The top cause of friction plate damage during installation is mishandling the transmission and input shaft when reinstalling the gearbox onto the engine.
- Where insufficient support for the gearbox's front can cause the input shaft to bear weight on the clutch plate.
- Where gearbox's rear is angled away from the clutch's center line.
- Where excessive force during input shaft installation, caused by misalignment of spline teeth or shaft, or inadequate lubrication is used.
Some other common ways damage to a clutch plate during installation might happen:
1) Misalignment: Worn dowels or dowel holes between the engine and transmission, damaged transmission support, or improper driveline angles can cause issues.
2) Rough Handling: Clutch plates are primarily torsionally strong but weak in other directions. Rough handling like knocks or drops can easily deform and damage them.
This is not intended to be an extensive nor exhaustive list of damage causes during installation.
AGE:
Like all automotive parts, clutch plates wear out over time due to factors related to their design and operation. Operating in high-temperature conditions, especially during frequent gear changes or under heavy loads, causes thermal cycling that alters the structure and strength of the clutch components, leading to degradation.
ENVIRONMENTAL FACTORS:
Exposure to corrosive environments reduces the lifespan and weakens man-made items. Clutches, predominantly metal-based, readily oxidize when exposed to water, hastening rust formation. Limited options exist to prevent oxidation in clutches due to the intense heat and friction they endure. Salt environments exacerbate corrosion issues.
Unfortunately, most people only learn about centrifugal disintegration after they have experienced it. To reduce the chances of its occurrence it is imperative to for vehicle owners to adhere to recommended maintenance schedules, drive responsibly, and ensure that the clutch system is properly maintained. Regular inspections and prompt repairs or replacements can help mitigate chance of occurrence due to age and environmental factors.
It is essential for vehicle owners to select a trained and experienced clutch installer who will follow the vehicle’s and parts manufacturer’s guidelines closely and take the proper steps to avoid mistakes that could potentially damage the clutch friction plate through improper installation.
While possible, it is extremely rare that a clutch friction plate will disintegrate due to a manufacturing defect. Should you believe that none of the aforementioned factors caused or contributed to the part failure, please contact your store. They are best suited to provide swift resolution, and expert assistance.