482 / 1133
CLUTCH
14
1.6. 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