DEFINITION: Clutch does not disengage completely to allow smooth shift operations. May cause gear clashing while the vehicle is not moving, at idle, and shifting out of neutral, or hard shifting in and out of gears while driving the vehicle. If equipped with a clutch brake, may not allow shifting out of neutral without transmission gear clashing.

Review the Symptoms - Clutch and perform the necessary inspections.

Pedal blocked from full travel

1. Inspect for obstacles that will prevent the pedal from going to the floor.
2. Clear any obstacles from under pedal area, such as floor mats or interior panels.
3. Adjust the pedal stops and switches, if equipped, to achieve full pedal travel.

Linkage blocked from full travel

1. Inspect for objects that may be lodged in the linkage, such as wire harnesses or hoses.
2. Remove any blockage.

Linkage requires adjustment

1. Inspect the release bearing for being adjusted properly. Refer to Clutch Assembly Adjustment .
2. Adjust the linkage for correct gap between the yoke or fork and the release bearing.

Linkage worn or damaged

1. Inspect the clutch pedal for worn components.
2. Repair or replace the clutch pedal components. Refer to Clutch Pedal Replacement .
3. Inspect the clutch lever linkage for wear or damage.
4. Repair or replace the worn linkage components.
5. Inspect the clutch housing cross shaft and bushings for wear.
6. Replace the clutch cross shaft and bushings.
7. Inspect the clutch release yoke or fork for wear.
8. Replace the worn clutch release yoke or fork. Refer to Clutch Fork Assembly Replacement .

Damaged clutch assembly components

1. Remove the clutch assembly and inspect the clutch assembly components. Refer to Clutch Assembly Replacement .
2. Inspect the clutch assembly components for the following damage:

•	Damaged clutch disc hub splines

•	Bent clutch disc

•	Bent drive straps

•	Broken or warped pressure plate

3. Replace the clutch assembly if any of the above damage is found. Refer to Clutch Assembly Replacement .

Contamination or grease in the release bearing bore

Clean the release bearing bore and the transmission input shaft.

Excessive side loading on the release bearing

1. Inspect the following clutch system components:

•	Worn or damaged cross shaft bushings

•	Worn or damaged cross shaft

•	Worn, damaged, or bent release bearing yoke

•	Uneven release bearing yoke contact wear pads

•	Worn or damaged pilot bearing

•	Excessive flywheel runout

•	Excessive engine to transmission misalignment

2. Repair or replace the component if found faulty.

Faulty pilot bearing

Replace the pilot bearing. Refer to Clutch Pilot Bearing Replacement .

Transmission input shaft splines worn or damaged

Replace the transmission input shaft. Refer to the transmission manufacturers service manual.

Tight or contaminated clutch disc splines

1. Clean the clutch disc and input shaft splines.
2. If the clutch disc will not clean, replace the clutch assembly. Refer to Clutch Assembly Replacement .

Flywheel housing to clutch housing excessive misalignment

1. Inspect the housing for being faulty.
2. Replace the housing if faulty. Refer to Clutch Housing Replacement .

Grease or oil contamination on the clutch discs facing

1. Repair the oil leak.
2. Repair the grease leak.
3. Clean the clutch disc facing and the other clutch assembly components.
4. Replace the clutch assembly if it will not clean. Refer to Clutch Assembly Replacement .

Cable brackets loose or faulty

1. Inspect the cable brackets for being bent, cracked or loose.
2. Repair or replace the cable brackets. Refer to Clutch Cable Return Spring and/or Bracket Replacement .

DEFINITION: The clutch does not disengage completely to allow smooth shift operations. May cause gear clashing while the vehicle is not moving, at idle, and shifting out of neutral, or hard shifting in and out of gears while driving the vehicle.

Review the Symptoms - Clutch and perform the necessary inspections.

Pedal blocked from full travel

1. Inspect for obstacles that will prevent the pedal from going to the floor.
2. Clear any obstacles from under pedal area, such as floor mats or interior panels.
3. Adjust the pedal stops and switches, if equipped, to achieve full pedal travel.

Linkage blocked from full travel

1. Inspect for objects that may be lodged in the linkage, such as wire harnesses or hoses.
2. Remove the blockage.

Linkage requires adjustment

Adjust the cable for no gap between the yoke and the release bearing.

Linkage worn or damaged

1. Inspect the clutch pedal for worn components.
2. Repair or replace the clutch pedal components. Refer to Clutch Pedal Replacement .
3. Inspect the clutch lever linkage for wear or damage.
4. Repair or replace the worn linkage components.
5. Inspect the clutch housing cross shaft and bushings for wear.
6. Replace the clutch cross shaft and bushings.
7. Inspect the clutch release yoke for wear.
8. Replace the worn clutch release yoke. Refer to Clutch Fork Assembly Replacement .

Damaged clutch assembly components

1. Remove the clutch assembly and inspect the clutch assembly components. Refer to Clutch Assembly Replacement .
2. Inspect the following clutch assembly components for damage:

•	Damaged clutch disc hub splines

•	Bent clutch disc

•	Bent drive straps

•	Broken or warped pressure plate

3. Replace the clutch assembly if any of the above damage is found. Refer to Clutch Assembly Replacement .

Contamination or grease in the release bearing bore

Clean the release bearing bore and the transmission quill tube.

Excessive side loading on the release bearing

1. Inspect the following clutch system components:

•	Worn or damaged cross shaft bushings

•	Worn or damaged cross shaft

•	Worn, damaged, or bent release bearing yoke

•	Uneven release bearing yoke contact wear pads

•	Worn or damaged pilot bearing

•	Excessive flywheel runout

•	Excessive engine to transmission misalignment

2. Repair or replace the component if found faulty.

Faulty pilot bearing

Replace the pilot bearing. Refer to Clutch Pilot Bearing Replacement .

Transmission input shaft splines worn or damaged

Replace the transmission input shaft. Refer to Transmission Disassemble in Manual Transmission - ZF S6-650.

Tight or contaminated clutch disc splines

Clean the clutch disc and input shaft splines.

If the clutch disc will not clean, replace the clutch assembly. Refer to Clutch Assembly Replacement .

Flywheel housing to clutch housing excessive misalignment

1. Inspect the housing for being faulty.
2. Replace the housing if faulty. Refer to Clutch Housing Replacement .

Grease or oil contamination on the clutch discs facing

1. Repair the oil leak.
2. Repair the grease leak.
3. Clean the clutch disc facing and the other clutch assembly components.
4. Replace the clutch assembly if it will not clean. Refer to Clutch Assembly Replacement .

Cable brackets loose or faulty

1. Inspect the clutch cable brackets for being bent, cracked or loose.
2. Repair or replace the cable brackets. Refer to Clutch Cable Return Spring and/or Bracket Replacement .