SAFARI BSVI SERVICE MANUAL

CLUTCH 5 9. GENERAL SYMPTOMS DIAGNOSIS A. CLUTCH GRAB / CHATTER COMPLAINT CAUSES REMEDY Clutch disc facing covered with oil or grease Oil leak at engine rear main or transaxle input shaft seal. Correct leak and replace modular clutch assembly. Too much grease applied to splines of disc and input shaft. Apply lighter coating of grease to splines. No fault found with clutch components Problem actually related to suspension or driveline component. Further diagnosis required. Check engine/transmission mounts, suspension attaching parts and other driveline components as needed. Engine related problems. Check electronic fuel injection and ignition systems. Partial engagement of clutch disc Clutch cover, spring, or release fingers bent, distorted (rough handling, improper assembly). Replace clutch assembly. Clutch disc damaged or distorted. Replace clutch assembly. Clutch Misalignment. Check clutch housing to engine dowels and dowel holes for damage. Correct as necessary. B. CLUTCH SLIPS COMPLAINT CAUSES REMEDY Disc facing worn out Normal wear. Replace clutch assembly. Driver frequently rides (slips) clutch, results in rapid wear, overheating. Replace clutch assembly. Insufficient clutch cover diaphragm spring tension. Replace clutch assembly. Clutch disc facing contaminated with oil or grease Leak at rear main oil seal or transaxle input shaft seal. Replace leaking seals. Replace clutch assembly. Excessive amount of grease applied to input shaft splines. Apply less grease to input shaft. Replace clutch assembly. Road splash, water entering housing. Seal housing. Inspect clutch assembly. Concentric Slave Cylinder leaking hydraulic fluid. Replace Concentric Slave Cylinder (CSC). Clutch is running partially disengaged Release bearing sticking or binding, does not return to normal running position. Verify that bearing is actually binding. Then, replace bearing and transmission front bearing retainer if sleeve surface is damaged. Concentric Slave cylinder (CSC) binding. Replace Concentric Slave cylinder (CSC).