Transmission Systems

Clutch kit

Valeo’s Transmission Systems quality, performance and expertise for traditional kits

More powerful engines, longer ratios and new lifetime specifications have led to the development and introduction of more complex clutch designs such as Valeo SAT (Self-Adjusting Technology). The SAT is a Valeo revolutionary technology that uses a self-adjusting facing wear compensation device on the pressure plate, thereby enhancing the clutch life and improving the pedal comfort. Valeo also supplies its self-adjusting technology to truck manufacturers.

As an aftermarket solution provider, Valeo engineers have designed a new clutch kit named HEC (High Efficiency Clutch) to replace the competitors’ self-adjusting clutch and give full satisfaction in terms of quality, reliability and durability. This is done by using an improved cover assembly and a low-wear facing (range from 190 mm to 260 mm), resulting from years of research in Valeo’s R&D centers. This solution does not require a specialist tool, which facilitates the fitting operations.

Today, over 3,400 part numbers (kits and components) cover 91% of the total car range, with a major presence within all major car makers such as French, German, Korean, Japanese, Italian manufacturers. Choose Valeo A wide Traditional clutch kits range :

3PKIT including concentric slave cylinder (CSC): 100 part numbers available

Self adjusting technology (SAT): 205 part numbers available of which high efficiency clutch (HEC): 65 part numbers available

CV clutches: 700 part numbers available of which 100 part numbers are remanufactured

An expanding offer for Korean and Japanese car application : Valeo provides large business opportunities with Asian applications. With the same level of quality and services as Valeo’s other ranges. Valeo is investing in all product lines to vastly extend its offer for Korean and Japanese vehicles and help you to rationalize your sourcing. Thanks to the range including over 670 kit part numbers, Valeo's estimated Asian car range coverage is now at 80%. New references include mainly traditional clutch kits and cover all vehicle generations. Some well-known applications are available for Hyundai Accent, Nissan Micra, Daewoo Matiz, Suzuki Grand Vitara and Toyota Aygo & Yaris and many more.

Major expertise : Reman range for Commercial Vehicles Valeo remanufactures the Commercial Vehicles clutch kit especially the large diameter over 330 mm. The remanufacturing process is integrated into our facility that assembles the OE clutch kits. Having implemented an efficient collection process all over Europe, Valeo is able to get the cores from all its customers and to help to save up to 50 kilos of raw material per kit (up to 90 kilos for twin disc kits). After collection, all the cores are sorted, dismantled and cleaned, and, before the re-assembling in the production line, the components are submitted to test on benches. The Reman process strictly fulfills the same specifications set for OE.

Service kit for conversion kit

KIT4P, the conversion kit by Valeo Transmission Systems, on DMF segment.

Valeo KIT4Ps offer a high performing aftermarket alternative to the DMF which matches its performance over its lifetime. This Valeo aftermarket innovation is celebrating over 10 years of success.

The KIT4P design is composed of a rigid flywheel - with no wear parts - after eliminating the need the flywheel has been replaced. In order to provide the same clutch function, maximum engine torque transfer and full gearbox protection, KIT4P contains a clutch kit made of Valeo’s long travel damper technology, which is widely used by Valeo as original equipment.

Recent KIT4P developments cover great applications such as, BMW 1,3,5 Series, Opel / Vauxhall Corsa, Meriva, Combo 1.3CDTi, Opel Agila, Citroën C2,C3,C4,C5, Xsara Picasso, Ford Mondeo III 2.0D, 2.0TDi, Suzuki Swift, Ignis II, Volvo S40, Mistubishi Carisma and Audi A3 & TT.

Valeo has also launched KIT4P including concentric slave cylinders (CSC) for vehicles fitted with a full hydraulic actuation system. Today, 14 references are in the range and it will continuously grow to enable a complete replacement kit to be brought onto the market. Valeo also offers a complete range of service kits to enable an individual clutch replacement.

Today, 98 KIT4P / conversion kit references are in Valeo’s range, covering more than 40 million vehicles in Europe, making Valeo a valuable transmission systems partner. Thanks to long travel damper disc, KIT4P is an economical alternative solution to DMF, matching its performance over lifetime and reducing repair and maintenance costs in the long run.

Choose Valeo :

Economic alternative

Extremely reliable solution providing full gearbox and engine protection

Increased durability and clutch life thanks to low wear and tear, and better thermal resistance

100% torque transfer in all drive conditions providing an important safety factor

Comfortable solution with high filtration of vibration and noise to enhance driving pleasure

Reduced labor and optimized serviceability thanks to the Valeo Service Kit

Easy to fit, same installation and fitting time as DMF and the associated clutch kit

Dual mass flywheels (D.M.F.)

Improve driver comfort and reduce torque vibrations thanks to dual mass flywheel (DMF) by Valeo transmission systems.

Dual mass flywheel for the best vehicle efficiency and driver comfort. Every second car which rolls off the assembly line is fitted with a DMF - this equipment rate is continuously increasing. The dual mass flywheel helps filter out dynamic vibrations between the engine and the gearbox. Thanks to two independent flywheels connected via a bearing or bushing, including a damper system, DMF proofs the sensitive gearbox and rest of vehicles against the engine explosions’ vibrations, thus improving driving comfort. Choose Valeo :

Designed for long lasting performance. High-grade “best-in-class” spring wire used. Long-life ball bearings and bushings (no maintenance needed). Added friction damping system design is stable for life Specifically designed for each vehicle application. Tuned with low stiffness for maximum noise reduction. Optimized filtering performance for “rattling” and “booming” issues. Applications from 200Nm up to 500Nm torque engines Improved driving comfort. Improved gear shift comfort and gearbox synchronizer durability by reduction of clutch disc inertia. Fuel consumption reduction is achieved by driving at lower speeds due to excellent noise reduction.

Among its latest launches, Valeo provides applications such as Peugeot 308, Citroën C4, Opel Astra, Mercedes A-B-C-S Class Valeo proposes 3 innovative solutions: DMF with inner damper : At high engine speeds, the centrifugal load pushes the springs against the spring guides and creates friction. Due to this friction, the active number of coil springs is reduced, therefore, the effective spring stiffness is increased and filtering capacity is reduced. In the DMF with inner springs, small straight springs are integrated in the drive plate. Less sensitive to the centrifugal load, they are able to filter the vibrations.

For some extremely demanding applications and especially on rear wheel drive (RWD) vehicles, it is necessary to obtain an extremely low level of vibration at the gearbox entry level. Valeo’s long travel damper (LTD) technology, developed for automatic transmission damping, is integrated in the DMF to reach this target. Long travel damper DMF : The LTD DMF significantly reduces perceived vibrations and engine noise. This represents a major step forward in powertrain filtration technologies.

This advance is especially important as the fuel-saving engines now being developed have higher torque and, consequently, generate greater vibrations, particularly at low speeds. The LTD DMF absorbs torque vibrations generated by the engine to the transmission, thereby increasing the comfort of the vehicle's occupants. Two compact filtration devices give the LTD DMF the qualities required to become an essential component in tomorrow's conventional high-performance engines as well as for hybrid powertrains, which have the strictest installation constraints. The LTD technology is based on two sets of three springs operating in series and synchronized by a back plate. The straight springs are less sensitive to the centrifugal load than the curved springs. This provides less friction, hence the filtering is better than the one with curved springs.

In addition to the known dual mass flywheel technology, the LTD DMF integrates a long travel damper developed by Valeo for torque converters in automatic transmissions. This combination allows it to provide optimal filtration, especially during the startup, thanks to a maximum angular displacement of 80°, as well as an exceptional performance level in all engine regimes. Valeo’s long travel damper dual mass flywheel offers comfort levels which had never been achieved previously on the most fuel-efficient engines.

The NVH (Noise-Vibration-Harshness) level and ease of gear changes offer remarkable driving comfort for even the most vibration prone engines. Flexible Flywheel: The crankshaft bends under the force of the strong combustions inside the engine cylinders. This generates wobbling of the axis on the flywheel, which is bolted to the end of the crankshaft. Stress occurs between the bearings and the crankshaft, generating vibrations. If not filtered, the result is a roaring noise caused by the engine, a flywheel axial vibration and a potential increased vibration on the clutch pedal.

The flexible flywheel filters the axial vibrations transmitted through the engine crankshaft. This is achieved by adding a flexible plate at the engine side of the flywheel mass. The crankshaft deformation continues, but is not transmitted to the flywheel thanks to the flexible plate leading to reduced engine noise at high engine speeds, a reduced bending stress on crankshaft and a reduced level of vibration on the clutch pedal.

Concentric slave cylinders (C.S.C.)

CSC, clutch slave cylinder by Valeo transmission for full-hydraulic systems

Along with technologies and new car manufacturers’ requirements, it has become difficult to fit a cable in a straight line between the pedal and the lever. That’s why more and more cars are now using hydraulic systems. These are much more flexible and reliable compared to manual systems. First, they enable an optimal and constant pedal effort.

Second, the used material is much lighter (up to 70% reduction of weight compared to the standard clutch system command) as well as much more compact. This is the main reason why this technology is easier to implement on OE projects. In response to this market trend, Valeo has developed a wide range of hydraulic parts: clutch master cylinder (CMC), clutch release cylinder (CRC) and clutch slave cylinder (CSC). Both the clutch master cylinder and the clutch release cylinder are used in “semi-hydraulic” system, whereas a “full hydraulic” system uses CMC and clutch slave cylinder.

In 2017, 131 million of vehicles are expected to be equipped with a CSC. Hence Valeo offers a range of over 150 part numbers covering key applications such as for Fiat 500, Punto, Ford Fiesta, Focus, Hyundai Sonata, Mercedes A Class, Opel Corsa, Renault Clio, Megane, Ssangyong Actyon and Volkswagen Transporter. As in the “semi hydraulic” system, the full-hydraulic system is based on the same principle as hydraulic brakes and consists of a transmitter (the CMC), a hose and a receiver. In “full-hydraulic”, the receiver is a concentric slave cylinder (CSC).

The CSC is a hydraulic cylinder with an integrated release bearing which eliminates the clutch lever and the conventional release bearing. It is connected to the master cylinder via the hose. The CSC is in direct contact with the clutch cover diaphragm, increasing the efficiency of the hydraulic system.

Advantage of the CSC is to eliminate the fork and the release bearing. There are no more deformations of the fork under load and the release system efficiency is increased. Therefore the pedal load is reduced. The CSC is concentric to the gear box input shaft. This also reduces the number of components which facilitates the assembly on the vehicle. Until 95’s, the clutch hydraulic release system technology was similar to the brake hydraulic technology and consisted of a master cylinder in aluminum and a cast iron release cylinder connected with a pipe made of steel and rubber.

The weight of the sub assembly is about 1,000 grams. The full function with bearing, fork and guiding tube, weighs about 1,700 grams. From early 95’s the widespread use of plastic materials and of CSC, both weight and costs of the parts are considerably reduced. From now on, the total weight of the sub assembly (CMC, pipe, CSC) is up to around 400 grams.

Due to the disappearance of the release bearing, the fork and the guiding tube, the complete hydraulic function reduced its weight by 75%. Valeo Info As the CSC is located inside the transmission housing, the replacement of the part is much longer (same time as a clutch replacement) than in the semi-hydraulic systems. Therefore, you should systematically change the CSC when replacing a clutch.