January 22, 2020 by clutchindustries ·
0 Comments
Trouble Shooting Clutch Systems
Section #1 Noise
Noise while depressing clutch pedal
Cause
-
Off centering of the release bearing or mis-alignment of the main shaft.
Repair
-
Replace the release bearing.
-
Realign the engine and the gear box.
Section #1 Loss of Drive
Cushion Plate broken
Cause
-
The disc has been distorted when refitting the gear box on the engine.
-
The engine and the gear box are misaligned.
-
The pilot bearing is damaged.
-
Aggressive driving.
Repair
-
Replace the clutch kit.
-
Realign the engine and the gear box.
-
Replace the pilot bearing.
Caution
-
Be careful in selecting the gears and do not over run the clutch.
Clutch disc plate broken
Cause
-
Defective clutch installed or wrong direction for installation.
Caution
-
Make sure that the correct kit is used on the application.
Section #2 Noise
Noise when in neutral
Cause
-
Lack of care during installation, splines have been damaged by the gear box main shaft.
Repair
-
Replace the main shaft.
-
Replace the clutch disc.
Caution
-
Make sure that the splines properly match up.
-
Lubricate with a proper quantity of grease.
Noise during release
Cause
-
Seized / worn pilot bearing / bushing.
Caution
-
Replace pilot bearing / bushing.
Release bearing damaged
Cause
-
Seal torn.
-
Overheating during slippage.
Leakage of the grease.
Damper spring break away
Cause
-
Wrong clutch cover size used.
-
Excessive release travel.
-
The clutch disc is installed on the wrong side.
Unusual worn out on the torsion spring area
Cause
-
Over torque applied to the clutch disc.
Section #3 Slipping
Burn marks on the flywheel
Cause
-
Excessive greasing of the spline hub when installed.
Repair
-
Clean the flywheel and replace the clutch disc.
Caution
-
Apply the correct amount of grease on the clutch disc splines and the input shaft
Section #3 Slipping & Chattering
Clutch facing completely worn
Cause
-
Use over product lifetime.
-
Prolonged clutch slippage due to a malfunction or extremely severe use. Disc not changed during a previous flywheel / cover replacement.
Clutch lining damaged
Cause
-
Excessive slippage due to aggressive driving or overloading.
-
The clutch operating system is badly adjusted or defective.
Repair
-
Replace the clutch kit.
-
Replace or machine evenly the flywheel.
Burn marks on the pressure plate
Cause
-
Oil or grease contamination on the clutch linings or on the pressure plate.
Repair
-
Locate and repair all sources of contamination.
-
Replace the clutch kit.
Caution
-
Apply the correct quantity of grease on the clutch disc splines and the input shaft. Do not use contaminated pair of gloves.
Circular grooves appearing on the pressure plate
Cause
-
Linings worn out, heads of the facing rivets are in contact with the pressure place.
Clutch lining contaminated with oil or grease
Cause
-
Excessive greasing of the spline hub when installed.
-
Oil leakage from engine or gear box.
Repair
-
Replace the clutch disc.
-
Locate and repair all sources of contamination.
Caution
-
Apply the correct amount of grease on the clutch disc splines and the input shaft.
Deformation of the clutch disc
Cause
-
Deformed during delivery or handling.
-
Deformed during installation. (weight of the gear box, dropped)
-
Deformation due to overheating during slippage.
Caution
-
Handle with care.
-
Do not place the clutch disc under a weight.
Section #4 Difficulty changing gears
Difficulty changing gears
Cause
-
The cover assembly has been dropped.
Repair
-
Install new clutch.
-
Always inspect the drive straps for damage before installation.
The drive straps of the clutch cover are damaged
Cause
-
Dropped during installation / overload.
-
Using improper product.
-
Improper gear selection. (ex: from 5th to 1st)
Repair
-
Replace the clutch disc.
-
Careful handling.
-
Operate to normal conditions.
Difficulty changing gears
Cause
-
The transmission was forced into position damaging the splines of the disc hub.
Repair
-
Install new clutch and carefully control the position and alignment of the transmission during installation.
-
Use a transmission jack and possibly install temporary guide pins to assist in aligning the transmission to the engine.
Section #5 Others
Too much grease
Cause
-
Excess of lubrication grease on the nose of the release bearing.
Repair
-
Clean the release bearing.
-
Apply the correct quantity of lubricant.
Over torque
Cause
-
Excessive engine brake operation.
-
Incorrect disc for the application.
-
Aggressive starting operation.
-
The clutch operating system is badly adjusted or defective (clutch pedal)
Repair
Difficulty shifting
Cause
-
Incorrect release bearing travel.
-
The clutch operating system is badly adjusted or defective.
-
The level of pre-load on the release bearing is incorrect.
Repair
-
Adjust the clutch operating system (pedal height, self adjusting system, clutch linkage..) check the pre-load on the release bearing.
Clutch pedal binding
Cause
-
The fork is out of shape.
-
The release bearing guide tube is worn or the release arm / fork is bent / worn.
Repair
-
Replace by a genuine release fork.
-
Install new clutch and guide tube.
-
Inspect all release bearing system components and repair or replace as needed.
The contact point of the fork is worn out, the fork is off-centered
Cause
-
The fork is out of shape.
Repair
-
Replace by a genuine release fork.
