678 / 1906
CLUTCH
12
3.1.1.5 GENERAL SYMPTOMS DIAGNOSIS
COMPLAINT
CONCERNS
CAUSES
REMEDY
1.NEW CLUTCH : DIFFICULTY IN CHANGING GEAR
Difficulty in
changing gear,
following the
replacement of
clutch.
Burrs thrown up around
splines
causing
stiff
movement on input shaft.
Due to poor alignment of
the gearbox on reassembly.
Always use clutch
aligning mandrel while
assembling the clutch.
The driven plate was
improperly aligned.
Do not force the
gearbox but rotate the
flywheel or gearbox
shaft to line up input
with splines.
Aggressive location of shaft
into hub.
Impossible to
change the gear
The pressure plate or clutch
cover has been damaged
and broken.
Aggressive driving
Avoid
aggressive
driving and educate
the driver.
Driving with foot resting on
clutch pedal
Inform the driver to
change his habit.
Excessive slipping has
resulted in overheating of
all components. The
pressure plate and CSC
has fractured due to
excessive heat
Replace
all
the
affected parts.
2. LOSS OF DRIVE : WITH RECENTLY FITTED CLUTCH
Loss of drive and
loud Clatter, even
though vehicle has
covered only a few
kilometers.
The centre hub of the
driven plate has ripped out.
The weight of the gearbox
has been hung on the
clutch assembly. This has
distorted the driven plate
resulting in failure within a
short period of use.
Ensure
that
the
gearbox shaft and
gearbox are not hung
on the clutch driven
plate by using a pit
jack or trolley jack to
support the gearbox
on reassembly.
Educate the driver.
Do not tow heavier
vehicle.
Very aggressive clutch
control. i. e. “Racing starts"
or towing a heavier vehicle.
3. SLIPPING CLUTCH
Clutch slips but the
hydraulic system is
proper.
The clutch friction
material is contaminated
There is an oil leak from the
engine or gear box
Replace the damaged
engine or gearbox oil
seals.
The clutch cover and
flywheel have blue colored
patches. Friction material
worn out excessively.
Aggressive driving
Avoid
aggressive
driving and educate
the driver. Replace the
affected parts.
4. JUDDERING DURING PULLING AWAY
Clutch judder on
initial take up of
torque.
Oil or grease found
between the clutch disc &
clutch cover.
Excessive grease applied
on input shaft splines.
Only use the needed
amount and correct
type of grease
Avoid
excessive
lubrication which could
contaminate
the
frictional surfaces.