CLUTCH 4 3. DIAGNOSIS OF CLUTCH: IN THE VEHICLE THE COMPONENT CAUSES REMEDY 1. New Clutch: Difficulty in changing gear Difficulty in changing gear, following replacement of clutch shaft. Burrs thrown up around splines causing stiff movement on shaft. Due to poor alignment of the gearbox on reassembly. The driven plate was improperly aligned. Aggressive location of shaft into hub. Care with the centering of driven plate; use an appropriate clutch aligning tool. Do not force the gearbox but rotate the flywheel or gearbox shaft to line up input with splines. 2. Loss of Drive: With recently fitted clutch Loss of drive and loud clatter, only covered a few hundred kilometers. The centre hub of the driven plate has ripped out and possibly one or more of the springs have been pushed out. The weight of the gearbox has been hung on the centre plate. This has distorted the driven plate resulting in failure within a short period of use. Very aggressive clutch control .i.e. “Racing starts” or when towing a heavily laden trailer. Ensure that the gearbox shaft and gearbox are not hung on the clutch driver plate by using a pit jack or trolley jack to support the gearbox on reassembly. 3. Slipping Clutch Clutch slip. The control system is in good condition and correctly adjusted. The clutch friction material is contaminated with oil. There is an oil leak from the engine or gearbox. Carefully check the engine and gearbox oil seals. Replace seals if oil is present in bell housing. 4. Juddering During Pulling Away Clutch judder on initial take up of torque. Oil or grease found on the middle of clutch to driven plate. Excess grease applied on input shaft splines. Only use the correct amount and correct type of grease. 5. Juddering During Pulling Away Loss of Drive The friction material has come off from both sides (centrifuged). The facing has centrifuged. The shattered linings are lodged into cover assembly and loose in the bell housing. Some parts of the driven plate could be broken. Drive error – e.g. accidentally changing from 5th to 2nd gear at 85 miles per hour.
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