TROUBLE SHOOTING
Indicator:
Unable to dis-engage the clutch
Cause:
1. Improper driving practice
2. Sudden or accidental down shifting of gears (i.e. 5th gear to 2nd gear)
3. Constant “dropping” of clutch at extremely high RPM when taking off
4. Poor handling/shipping practice
Effect:
Bent drive/lifting straps
Action:
1. Replace clutch pressure plate or complete kit
2. Driver education
Indicator:
Loss of drive
Cause:
Clutch casting has had a total failure
Effect:
1. Excessive thermal overload
2. Incorrect driving practices
3. Clutch control failure
4. Driver error
Action:
1. Replace clutch kit
2. Check clutch control mechanisms and repair or replace if necessary
3. Driver education
Indicator:
Loss of drive/no transmitted power
Cause:
1. The clutch disc has had a toque overload (i.e 5th to 2nd at high speed)
2. Clutch release system failure (Clutch hydraulics/Clutch cable)
3. Incorrect clutch free travel
4. Overloading the clutch
5. Overloading the vehicle
Effect:
The clutch disc linings have had a total failure
Action:
1. Replace the clutch disc/kit (ensure all friction material is removed from the gearbox and back of engine)
2. Check and inspect all clutch release system mechanisms - repair or replace if necessary
3. Set clutch free travel to manufacturer’s specifications
4. Driver education
Indicator:
Clutch Shudder or Chatter
Effect:
Vehicle has severe shudder or chatter on take-off or/and between gear selection
Cause:
1. If new clutch has been fitted on an old flywheel without machined (resurfaced), then this may cause the shudder (please note: flywheels which are not machined may affect the clutch warranty)
2. Incorrect flywheel machining (i.e machined on a lathe)
3. Clutch disc may have oil/grease contamination
4. Engine and/or transmission mounts are worn or damaged
5. Incorrect break-in (bedding-in) procedure
Action:
1. Check engine and transmission mounts-repair or replace as necessary
2. Check for any engine or transmission oil leaks that can impact on the clutch (rear main seal, rocker cover or front transmission seal)-repair as necessary
3. All new clutch components must be in service for a minimum of 500 miles of normal driving for efficient break-in (bedding in).
Initiator:
Slipping Clutch / Shudder or Chatter
Cause:
1. Worn or failed rear main engine seal
2. Worn or failed front transmission seal
3. Excessive lubrication applied on clutch disc splines, input shaft or clutch release bearing
Effect:
Grease or oil contamination on clutch disc lining (facing)
Action:
1. Complete replacement of clutch pressure plate, disc plate and flywheel
2. Check rear main seal for leaking – replace if necessary
3. Check front transmission seal – replace if necessary
4. Check for any other engine oil leaks which could compromise transmission bellhousing (i.e. sump gasket, rocker cover and etc.)
5. Remove any excessive lubrication from clutch components once they have been checked for fitment.
Indicator:
Complete Loss of drive
Cause:
1. The clutch disc center has had a total failure
2. Friction facing have come off the clutch disc
Effect:
The clutch is unable to transfer the engine power through the driveline
Action:
1. Remove transmission
2. Identify the reasons for the failure (see Trouble Shooting Clutch Disc Loss of Drive)
3. Replace clutch kit and renew (machine flywheel) or replace any other clutch service components (flywheel/pilot bearing)
Indicator:
Difficulties changing gears
Cause:
1. Transmission misaligned (gearbox to engine dowels damaged or missing)
2. Damaged input shaft
Effect:
Damaged clutch disc spline teeth from incorrect alignment
Action:
1. Replace clutch disc plate
2. Check transmission to engine dowels pins are present and good working condition
3. Inspect input shaft for excessive wear and damage.
Indicator:
Difficult to engage/disengage gear, grating noise and hard pedal at the end of the operating stroke.
Cause:
1. Flywheel depth or step height incorrect
2. Clutch throwout (release) bearing has fallen off from clutch fork.
3. Incorrect clutch free travel (too much pre-load)
4. Faulty clutch hydraulics
Effect:
Diaphragm fouled on clutch disc. Crashing in gear and unable to obtain clutch adjustment.
Action:
1. Check flywheel depth or step height incorrect
2. Check for wear or damage to the clutch fork
3. Check clutch hydraulics and replace if necessary
4. Adjust clutch free travel to manufacturers specifications
Indicator:
Difficulties with selecting gear (including when a new clutch has been installed).
Cause:
1. The release of the clutch is insufficient (this will give a low clutch engagement)
2. The clutch hydraulics are preventing the clutch to operate efficiently
3. The clutch control system is not operating correctly allowing correct release (fork, worn pivot ball, worn clutch line or cable)
Effect:
The clutch disc is not fully released and still driving the transmission
Action:
1. Assess the master cylinder adjustment (most have an adjustable push rod to lengthen the operating stroke)
2. Bleed the system to remove any trapped air (bleeding tools may be required to bleed correctly)
3. Check the operating mechanisms to ensure they are serviceable and allowing the clutch to have optimum travel
Indicator:
Difficulties with selecting gear (including when a new clutch has been installed).
Cause:
1. The release of the clutch is insufficient (this will give a low clutch engagement)
2. The clutch hydraulics are preventing the clutch to operate efficiently
3. The clutch control system is not operating correctly allowing correct release (fork, worn pivot ball, worn clutch line or cable)
Effect:
The clutch disc is not fully released and still driving the transmission
Action:
1. Assess the master cylinder adjustment (most have an adjustable push rod to lengthen the operating stroke)
2. Bleed the system to remove any trapped air (bleeding tools may be required to bleed correctly)
3. Check the operating mechanisms to ensure they are serviceable and allowing the clutch to have optimum travel
Indicator:
Noise or squeaking coming from bellhousing or transmission area
Cause:
Poorly lubricated Clutch Fork, Pivot Ball, Throwout (Release) Bearing to fork contact area or bearing guide tube
Effect:
1. These noises will be identified when the clutch is engaged (foot off the pedal)
2. To check with the vehicle running and foot off the clutch pedal, if the noise is present press the clutch pedal - if the noise disappears then the likelihood of the bearing being at faulty is low. Please see ‘Action’ below for troubleshoot
3. To double check the problem lubricate the clutch fork/pivot ball and back of the release bearing with some spray lubrication. If the noise has disappeared then the likelihood of a bearing failure is eliminated. Please note spray lubrication is only a short term solution and the noise will come back with use. Please also be careful not to over lubricate the release components as it may compromise the clutch operation
Action:
1. Remove the transmission. Inspect all clutch control components - Repair or replace if necessary
2. Clean and lubricate all moving components in the clutch operation system. ClutchMax recommends lubricating grease which is available from your local auto parts store.
Indicator:
Slipping When Clutch Engagement or Disengagement
Cause:
1. Bellhousing has not been degreased and cleaned.
2. Improper installation of new clutch.
3. Excessive facing material from old disc have lodged in bellhousing or transmission casing area.
4. Missing or worn (mostly for 4-wheel drive vehicles) clutch fork cover boot on transmission.
Effect:
Worn clutch disc facing material and/or dirt lodged between diaphragm springs causing inoperable clutch pressure plate.
Action:
1. Bellhousing and engine crank area must be thoroughly degreased and cleaned prior to new clutch installation.
Indicator:
Slipping/Shudder, Poor clutch performance
Cause:
1. Overloading/Abusing the clutch
2. Overloading the vehicle
3. Incorrect clutch free travel
4. Clutch release system failure (Hydraulic/Cable)
5. Driver error
Effect:
Pressure plate casting has heat deterioration.
Action:
1. Replace clutch kit and machine flywheel
2. Check clutch control mechanisms and if necessary repair or replace
3. Driver education.
Indicator:
No gear selection/difficult engagement
Cause:
Retractor clip has become dislodged/stretched
Effect:
1. Over adjustment of clutch has caused the stretching of the retractor clip
2. The pressure plate has been dropped
3. The pressure plate has been damaged in transit
Action:
1. Replace clutch cover
2. Inspect the clutch operating adjustments
3. Always practice safe handling of the cover when fitting
4. Inspect the clutch cover prior to fitment to ensure there are no retractor clip issues
Indicator:
Sudden Clutch Failure.
Cause:
1. Faulty or worn pilot bearings or bushing
2. Hanging transmission during installation
3. Contamination between mating surfaces of the engine bolt up areas
4. Severe engine to transmission mis-alignment
5. Clutch disc overload (Shifting from 5th to 2nd at high speed)
6. Transmission failure
Effect:
Clutch hub failure.
Action:
1. Check pilot bearing and replace if necessary
2. Inspect engine to transmission dowels are serviceable and if damaged replace
3. Align clutch to the flywheel and take precaution when fitting the transmission
4. Ensure the engine and transmission have clean mating surfaces before installation
5. Check transmission for metal fragments then remove and repair parts in necessary
