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
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