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Tips for CLUTCHES, Clutch (Other), Clutch Discs DDC: Frequently Asked Questions (FAQ) and how it is implemented | Valeo Service

Technical Service Bulletin for CLUTCHES, Clutch (Other), Clutch Discs, 855513 - Valeo Service

DDC: Frequently Asked Questions (FAQ)

<table border="1" cellpadding="1" cellspacing="1" class="DJ__responsiveTable__processed table">
	<thead>
		<tr>
			<th>Question</th>
			<th>Answer</th>
		</tr>
	</thead>
	<tbody>
		<tr>
			<td>
			Is this tooling mandatory for all Valeo DDC references?

			<img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823927-bc0shv550n-whr.jpg" />
			</td>
			<td>JA. 3 key reasons: 
			1. The space between the DDC kit and the gearbox housing is minimal and it is necessary to use the tool for removal and installation (impossible to do manually). 
			2. Actuator calibration: necessary to do that with the tool. 
			3. To ensure proper insertion of the kit into the gearbox, it is necessary to press down the DDC with the cylinder tool and the mounting tool secured to the gearbox housing. This also ensures that the bearing is placed correctly and is not damaged.</td>
		</tr>
		<tr>
			<td>Are there other suppliers for the Valeo DDC tooling?</td>
			<td>NO. The Valeo tool is the only dedicated tool for OES and IAM.</td>
		</tr>
		<tr>
			<td>
			When a DMF is replaced, it is recommended to replace the clutch kit as well and vice versa?

			<img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823930-mhes03uu7f-whr.jpg" />
			</td>
			<td>YES. Always. 1.Valeo recommends replacing the DDC kit and DMF (dual mass flywheel) at the same time. This prevents second repairs or problems such as vibrations. 2.If the DMF exhibits vibrations or imbalance, it directly affects the DDC, mainly the friction surfaces (non-parallel friction).</td>
		</tr>
		<tr>
			<td>Is aftermarket fitting procedure the same as in the brand channel (OES)?</td>
			<td>YES. Exactly the same.</td>
		</tr>
		<tr>
			<td>What is the adjustment tolerance for the actuator calibration process?</td>
			<td>In terms of tolerance: 0.5 mm above or below.</td>
		</tr>
		<tr>
			<td>
			Is a new actuator ready to be directly fitted, when coming out of the box?

			<img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823933-ldtdwvgqm3-whr.jpg" />
			</td>
			<td>YES. New actuator is delivered already calibrated for NEW DDC Kit. Two scenarios: 
			1.If you replace simultaneously actuator + DDC kit + DMF: Nothing to do 
			2.If you replace only the actuator (keeping old DDC kit): You need to measure with the tool the distance for the OLD actuator (distance of the old levers=discs wear) and you need to calibrate the NEW actuator according to the measurements taken from the old actuator, to ensure the lever will act with the mechanism. If you do not adjust, shifts will not work.</td>
		</tr>
		<tr>
			<td>If only the DMF is replaced, does the actuator need a calibration?</td>
			<td>NO. The actuator doesn´t need any calibration because you will keep the old DDC kit already adjusted with the actuator. But remember Valeo recommends to replace DMF and DDC at the same time.</td>
		</tr>
		<tr>
			<td>Is there grease supplied for hub in each box?</td>
			<td>YES. The grease (quantity and type) is supplied by Valeo inside the boxes.</td>
		</tr>
		<tr>
			<td>If only the actuator is replaced, but the clutch is used and is not replaced, do we use the same calibration procedure and set to distance as NEW?</td>
			<td>Be careful: a NEW actuator is calibrated for a NEW DCC kit (without disc wear). &nbsp;If you keep the old kit (with wear) : You need to measure with the tool the distance for the OLD actuator (distance of the old levers=discs wear) and you need to calibrate the NEW actuator according to the measurements taken from the old actuator, to ensure the lever will act with the mechanism. If you do not adjust, shifts will not work.</td>
		</tr>
		<tr>
			<td>
			What is the friction material used for DDC?

			<img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823936-wlpr7x3p7q-whr.jpg" /><img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823939-9sdgki91l1-whr.jpg" />
			</td>
			<td>1.It's a special Valeo grade that received an Innovation Pace Award in 2015. 
			2.The facing grade name is F910 , that is a special grade for making smoothly the transition between the gear ratios without any torque interruption, keeping in a high level the safety factor for torque transfer and mechanical resistance. 
			3.Both Clutches, ODD and EVEN , have the same facing material grade , that facilitates the comfortable transition between ODD and EVEN. 
			4.Dimensions and facings grade allow long life of DDC.</td>
		</tr>
		<tr>
			<td>Is there a different friction material for even and odd gears ?</td>
			<td>NO. Both Clutches, ODD and EVEN, have the same facing material grade, that facilitates the comfortable transition between ODD and EVEN.</td>
		</tr>
		<tr>
			<td>
			Do all actuators have the same calibration measurement?
			</td>
			<td>
			NO. It depends on the gearbox type:

			Medium 7 speed D7UF1 (most common): 71,5 - 72,5

			Small 7 speed&nbsp; D7GF1 (short production): 69,0 - 70,0

			HEV 6 speed D6KF1 :&nbsp; 82,0 - 83,0
			</td>
		</tr>
		<tr>
			<td>
			Are the discs dimensions for ODD and EVEN gears the same?

			<img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823942-mrcnaa7eww-whr.jpg" />
			</td>
			<td>
			NO.

			Dimensions (thickness and facing outside diameter) of C1 clutch facings for ODD gears (set 1-3-5-7) are reinforced, because the energy when engaging or reengaging is higher than for C2 clutch for EVEN and reverse Gears (set 2-4-6-R).

			e.g&nbsp; DDC for transmission D7UF1:

			1.Facing size :

			a.C1 (ODD) = 235 X 135

			b.C2 (EVEN) = 228.6 X 135

			2. Facings thickness:

			a.C1 (ODD) = 3.85mm

			b.C2 (EVEN) =3.19mm
			</td>
		</tr>
		<tr>
			<td>
			Will it be necessary to reset the vehicle with a Diag Tool after repair?
			</td>
			<td>
			NO.

			Calibration is fully mechanical. If the calibration has been done following Valeo requirements, the system will not have “default codes”.
			</td>
		</tr>
		<tr>
			<td>
			Are the symptoms for mechanical failures different for traditional clutches?

			<img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823945-ojtg698jw8-whr.jpg" />
			</td>
			<td>
			NO. The system is the same like a traditional clutch, excepted that a DDC is composed by TWO discs and TWO mechanisms (one for ODD gears, another for EVEN gears) which works like a traditional clutch.

			There are also TWO forks and TWO bearings for the engagement and disengagement, mechanical displacement like a traditional clutch

			Then the mechanical diagnostic will be the same as for traditional clutches.
			</td>
		</tr>
		<tr>
			<td>
			For Hybrid vehicles: is the repair the same?
			</td>
			<td>
			YES. The unique difference you will find: the Hybrid model has a “coupling rotor” (for electric mode) between flywheel and DDC kit.

			The tool to place the coupling rotor is included in tooling set.

			Valeo offers the new coupling rotor in its range.
			</td>
		</tr>
		<tr>
			<td>
			Which is the difference between&nbsp; a DMF for traditional clutches and a DMF for DDC?

			<img alt="" src="https://assets-valeo.keepeek.com/pm_8143_823_823948-fa7s2bp8bu-whr.jpg" />
			</td>
			<td>
			1.The torque transfer between a DMF and a traditional clutch is made by “friction”. In the case of a DDC, it is made by “ring gear”

			2.During the fitting process, make sure that DMF and DDC kit are correctly linked, before tightening the bolts.
			</td>
		</tr>
	</tbody>
</table>