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Teknik
Diagnose common clutch symptoms — cause and remedy.
Cause: 1) Faulty driveshaft oil seal 2) Faulty rear main oil seal 3) Incorrect grease used to lubricate splines on input shaft 4) Excess grease used to lubricate splines on input shaft
Solution: 1) Replace contaminated clutch 2) Replace faulty oil seals 3) Use grease specified by the manufacturer (high melting point grease) 4) Lightly grease input shaft and remove excess grease during installation
Cause: 1) Improper driver technique 2) The speed of the vehicle exceeded that capable of the selected gear 3) Accidental selection of lower gear during down shifting at higher road speeds (e.g. from 5th to 2nd gear)
Solution: 1) Replace clutch kit and driver education / improved driver technique required
Cause: 1) Faulty or worn spigot bearing or pilot bush 2) Hanging of gearbox during installation 3) Dirt or chips between mating surfaces of the motor and bell housing 4) Worn or missing flywheel dowel(s)
Solution: 1) Replace spigot bearing or pilot bush 2) Align and install gearbox with the assistance of a transmission jack 3) Always clean mating surfaces to avoid misalignment during clutch installation 4) Check flywheel dowels
Cause: 1) Overloading vehicle 2) Friction disc has been replaced but not clutch pressure plate assembly
Solution: 1) Do not overload the vehicle 2) Replace clutch kit
Cause: 1) Incorrect bedding-in procedure 2) Contamination of the friction facings with grease and/or dirt
Solution: 1) Adhere to correct bedding-in procedure 2) Replace clutch kit
Cause: 1) Friction disc not tested correctly on input shaft before installation 2) Missing spigot bearing or pilot bush
Solution: 1) Always check the number of spline teeth and smooth sliding on input shaft 2) Replace spigot bearing or pilot bush
Cause: 1) Clutch cover pressure plate assembly hold down bolts to assist ease of installation have not been removed
Solution: 1) Remove hold down bolts during installation of new clutch
Cause: 1) Incorrect clutch travel adjustment 2) Driver resting foot on clutch pedal 3) Quill shaft worn / bearing stuck on worn spot and not returning to original position 4) Clutch slave cylinder corroded or worn and piston not returning to allow free travel 5) Stretched or sticking clutch cable
Solution: 1) Adjust clutch to specification 2) Driver education 3) Replace quill shaft (gearbox bearing guide tube) 4) Replace clutch slave cylinder and replace hydraulic fluid 5) Replace clutch cable (do not re-oil old cable)
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Cause: 1) Flywheel friction surface not even 2) Flywheel has not been machined (deep scoring from previous clutch does not allow even connection with the running surface) 3) Misalignment
Solution: 1) Always resurface flywheel (single mass flywheels only) or replace (dual mass or flex flywheels) before installing the new clutch and ensure correct alignment
Cause: 1) Faulty driveshaft oil seal 2) Faulty rear main oil seal 3) Incorrect grease used to lubricate splines on input shaft 4) Excess grease used to lubricate splines on input shaft
Solution: 1) Replace contaminated clutch 2) Replace faulty oil seals 3) Use grease specified by the manufacturer (high melting point grease) 4) Lightly grease input shaft and remove excess grease during installation
Cause: 1) Installation error / driveline misalignment
Solution: 1) Replace clutch kit and spigot bearing or pilot bush 2) Avoid driveline misalignment on installation
Cause: 1) Incorrect clutch travel adjustment 2) Driver resting foot on clutch pedal 3) Quill shaft worn / bearing stuck on worn spot and not returning to original position 4) Clutch slave cylinder corroded or worn and piston not returning to allow free travel 5) Stretched or sticky cable
Solution: 1) Adjust clutch to specification 2) Driver education 3) Replace quill shaft (gearbox bearing guide tube) 4) Replace clutch slave cylinder and replace hydraulic fluid 5) Replace clutch cable (do not re-oil old cable)
Cause: 1) Improper driving practice (e.g. dropping the clutch) 2) Down-changing of gears (e.g. 5th gear to 2nd gear) 3) Driveline misalignment
Solution: 1) Driver education 2) Avoid driveline misalignment on installation
Cause: 1) Clutch wound past torque capacity
Solution: 1) Driver education 2) Install clutch with greater torque capacity for performance driving
Cause: 1) Defective spigot bearing/pilot bush resulting in driveline misalignment 2) Hanging the gearbox during installation 3) Not using a suitable alignment tool during installation
Solution: 1) Replace defective spigot bearing or pilot bush 2) Always use a transmission jack during installation 3) Always use a clutch alignment tool
Cause: 1) Hanging of gearbox during installation pulling the hub towards the transmission side 2) Not aligning clutch disc and forcing / pushing the first motion shaft into the hub of the clutch disc
Solution: 1) Always use a transmission jack during installation 2) Always use a clutch alignment tool when installing a clutch and do not force the gearbox input shaft into the friction disc splined hub
Cause: 1) Pull type ring mechanism has been dislodged during installation of the transmission 2) Pull type ring mechanism has been damaged during installation of the transmission and the bearing has disconnected from the cover assembly during operation 3) Bearing not clipped into ring mechanism correctly
Solution: 1) Always use a transmission jack during installation 2) After installing transmission, snap bearing into place by pulling back on the clutch fork or pedal - refer to manufacturer's official information 3) Ensure bearing is clipped in correctly
Cause: 1) Improper driving technique 2) Sudden down changing of gears / incorrect gear selection at high road speeds (eg. from 5th gear to 2nd gear) 3) Constant dropping of clutch at high engine revolutions during take off
Solution: 1) Driver education
Cause: 1) Incorrect clutch travel adjustment 2) Driver resting foot on clutch pedal 3) Quill shaft worn / bearing stuck on worn spot and not returning to original position 4) Clutch slave cylinder corroded or worn and piston not returning to allow free travel 5) Stretched or sticky cable
Solution: 1) Adjust clutch to specification 2) Driver education 3) Replace quill shaft (gearbox bearing guide tube) 4) Replace clutch slave cylinder and replace hydraulic fluid 5) Replace clutch cable (do not re-oil old cable)
Cause: 1) Cover assembly not torqued down correctly 2) Air tools used to torque down the cover assembly
Solution: 1) Always torque down cover assembly in a star pattern 2) Never use air tools to install a cover assembly
Cause: 1) Badly worn bearing carrier re-installed into vehicle
Solution: 1) Always check the bearing carrier for wear before replacing clutch kit and replace if necessary