The clearance between the clutch release bearing and the release lever is to ensure that the clutch can be properly released and engaged. This clearance is set so that when the clutch pedal is depressed, the clutch release bearing is able to push the clutch pressure plate sufficiently to interrupt the power transmission between the engine and the transmission, and the vehicle can shift or stop smoothly. Specifically, the amount of clearance depends on the requirements of the clutch design and the design of the release system.

Clearance between clutch release bearing and release lever

The clearance between the clutch release bearing and release lever is usually between 3mm and 4mm. This clearance is an important parameter in the clutch design and is essential for the proper functioning of the clutch.

Function of the clearance between the clutch release bearing and release lever

The clearance between the clutch release bearing and release lever exists for the following main purposes:

1. To compensate for friction plate wear:

As the clutch friction plates continue to wear, the release lever may buckle and press against the release bearing, resulting in pressure on the release lever, which in turn affects the clutch's disengagement and engagement effects. The presence of this gap compensates for the effects of friction plate wear and ensures that the clutch continues to engage reliably.

2. Ensure smooth engagement and gentle disengagement of the clutch:

Since the clutch pressure plate, release lever and engine crankshaft are synchronized, and the release fork can only move axially in the direction of the clutch output shaft, it is not possible to pivot the release lever directly with the release fork. Through the release bearing, the release lever can be made to move axially along the clutch output shaft while rotating, thus ensuring smooth clutch engagement and soft clutch disengagement, reducing wear and prolonging the service life of the clutch and the whole transmission system.

3. Forming the free travel of the clutch pedal:

This gap is manifested in the clutch pedal as a free travel. When the driver depresses the clutch pedal, he will first overcome this free travel before he can begin to actually disengage the clutch. The presence of this free travel helps the driver to control the clutch disengagement and engagement more precisely, improving driving comfort and safety.

4. Allows for motion deviation: 

During clutch operation, parts expand or contract due to temperature changes between the engine and transmission. The clearance allows these parts to expand and contract freely under temperature changes, reducing mechanical failures caused by thermal expansion.

5. Reduces wear: 

Proper clearance reduces direct contact between the release bearing and the release lever, which reduces wear between the two and extends the life of the components.

6. Enhances reliability: 

When the clutch is in operation, the clearance helps to minimize possible damage due to vibration and shock, increasing the reliability of the clutch system.

7. Ensure proper operation:

 The clearance between the clutch release bearing and release lever, if too large or too small, may affect the proper operation of the clutch, therefore, maintaining the proper clearance is essential to ensure the driving performance and safety of the vehicle.

The size of the clearance directly affects the performance of the clutch.

The clearance between the clutch release bearing and the release lever, often referred to as clutch play, is an important parameter in adjusting clutch performance. Too much or too little clearance can adversely affect clutch performance:

1. Too small a clearance:

   - May lead to incomplete clutch separation, so that the engine and transmission can not be completely separated, thus causing an increase in engine load and unstable power output.

   - It may cause excessive wear of clutch parts (such as release bearing and release lever) and shorten service life.

   - It may increase the pressure of the clutch pedal, making the driver feel that the clutch pedal is hard and inconvenient to operate.

2. Excessive gap:

   - May result in the clutch not being smooth enough when engaging, skipping gears or difficulty in shifting gears.

   - Excessive clearance may be created when the clutch is engaged, resulting in slipping between the clutch plates and increased wear on the clutch.

   - May not respond quickly enough to the clutch during emergency operation, such as hard braking or hard acceleration, affecting vehicle maneuverability.

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Therefore, the clearance between the clutch release bearing and the release lever needs to be adjusted according to the specific conditions of the vehicle and the manufacturer's recommendations to ensure that the clutch can work properly and efficiently within its operating range. When making adjustments, proper maintenance procedures and standards should be followed to ensure the safety and performance of the vehicle.

In summary, the clearance between the clutch release bearing and the release lever is an important consideration in clutch design, which not only compensates for the wear of the friction plate and ensures reliable clutch combination, but also improves the smoothness of clutch engagement and softness of clutch disengagement, reduces wear and prolongs the service life of the clutch and the entire transmission system.