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Clutch Tables & Guides

Clutch Troubleshooting, Failures, and Malfunctions Guide

Please take a moment to view the various informational tables below in regards to clutch troubleshooting, failures, malfunctions, and errors. If you are currently experiencing any of these or other technical issues with your product, please Contact Us as soon as possible, or locate your closest auto mechanic for assistance.

NOTE: The following tables are a guideline ONLY. They are intended for assistance in identifying the problems a product may have in order to seek out the best solution possible. The information presented is not intended to be a one-time, automatic fix of the issues currently occuring. For best results, please consult and seek out assistance from a trained automobile expert or mechanic.

 

Difficulty Changing Gears

CAUSEACTION NEEDED
The transmission was forced into position damaging the splines of the disc hub. Install a new clutch and carefully control the position and alignment of the transmission during installation. Use a transmission jack and possibly install temporary guide pins to assist in aligning the transmission to the engine.
The cover assembly has been dropped. Install a new clutch.  Always inspect the drive straps for damage before installation.
The cover assembly has been dropped. Install a new clutch and ensure all flywheel dowel pins are in position and in good condition. Do not use air tools to tighten the bolts.
The cover assembly has been dropped. Repair self-adjusting release system. Replace ratchet and pawl.
The cover assembly has been dropped. Inspect release mechanism for full travel or lost motion due to worn parts. A stamped steel release arm can wear and break. Always remove and check arm and external pivots. Install new fork bushings and lubricate as required with high melting point grease.


Loss of Drive

CAUSEACTION NEEDED
Transmission has been hung on the shaft during installation.  Angular misalignment of the transmission to engine. Install a new clutch and support transmission during installation.  Do not allow the transmission to hang on the clutch disc during installation.  Check for missing bell housing dowel sleeves, worn pilot bushing/bearing or foreign matter between transmission and engine including wires, cables or brackets.  The above problems will cause cracking in the segments, leading to separation of the damper and facing segments.
Driver resting foot on the clutch pedal resulting in release system sticking. Install a new clutch.  Check all components of the release system, particularly self-adjusting release systems, and guide tubes.  Check for leaking oil seals.
The clutch has been disengaged at speeds in excess of the maximum for the gear selected or the incorrect gear has been selected.  This has caused the facings to burst. Install a new clutch and educate the driver.


Noise & Vibration

SPECIFIC INCIDENTCAUSEACTION NEEDED
Noisy clutch. Broken location lug due to worn release fork and/or no lubrication. Replace any worn components and install a new clutch.  Apply a liberal amount of high temp grease to the fork contact pads.
Chattering after changing the clutch. Flywheel surface is worn. Replace or resurface flywheel and install a new clutch.
Grating noise when pulling away. No lubrication on the clutch fork contact areas. Clean and lubricate using the grease supplied with the clutch kit.
Noise when nuetral. Oil or grease has contaminated the disc pre-damper making it ineffective. Install a new clutch and sparingly use the spline grease supplied in the clutch kit.
Noise during release. Worn pilot bearing or bushing. Replace pilot bearing or bushing.
Noise. Installation is missing the transmission to engine dowel sleeves or pilot bushing/bearing.  This has created a concentric misalignment of the engine to the transmission.  The torsion damper is destroyed, damper springs are broken, stop pins show contact from the hub flange and the hub pilot is worn. Carefully inspect for missing dowel sleeves and worn dowel sleeve holes in the bell housing.  Replace pilot bushing/bearing and inspect the transmission to engine alignment.
Clatter on engagement. Excessive amount or incorrect type of grease applied to the input shaft. Install a new clutch and use the spline grease supplied in the clutch kit.


Clutch Slippage

SPECIFIC INCIDENTCAUSEACTION NEEDED
Slipping and impossible to change gear. Overheating due to excessive clutch slippage. Install a new clutch kit. Check all components of the release system, particularly self-adjusting release systems and guide tubes. Check for leaking oil seals.
Slippage and chattering. Driver resting foot on the clutch pedal or incorrect clutch adjustment. Do not use the clutch pedal as a footrest.  Inspect for correct clutch adjustment.
Slipping. The self-adjusting mechanism has become jammed. Replace or repair the self-adjusting mechanism or in the case of semiautomatic adjusters - reset.
Slipping. Clutch facing material is contaminated with oil. Replace leaking oil seals. Clean off excess oil and install a new clutch.


Clutch Pedal

SPECIFIC INCIDENTCAUSEACTION NEEDED
Vibration through the clutch pedal. The transmission shaft has struck and bent the diaphragm spring fingers during installation. Install a new clutch and carefully align and control the position of the transmission during installation.
Noise while depressing clutch pedal. Seized release bearing due to excessive heat caused by incorrect bearing pre-load, or, loss of grease. Install a new clutch and check all components and adjustments of the release system: i.e. cables, linkages, fork, ball studs, fork bushings, and self-adjusting release systems.
Clutch pedal binding. The release bearing guide tube is worn, or the release arm/fork is bent or worn out. Install a new clutch and guide tube.  Inspect all release system components and repair or replace any parts as needed.
Grating noise and stiff pedal. Insufficient lubrication of the clutch fork, particularly at the pivot point. Clean and lubricate all components using a high temperature grease.  If excessively worn, replace the fork and ball stud.
High pedal effort. The release bearing does not freely slide on the guide tube. Clean and lubricate the guide tube to bearing contact area with high temperature grease.  If the guide tube is worn or scored, replace the guide tube.
Metallic noise at bottom of pedal travel; difficulty in shifting. The release travel is excessive, causing the diaphragm spring to contact with the clutch disc. Install a new clutch. Ensure correct clutch adjustment.
Metallic noise at bottom of pedal travel. The release travel is excessive, causing the diaphragm spring to contact with the bearing carrier. Install a new clutch. Ensure correct clutch adjustment.

 


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