DEFINITION: The clutch does not engage completely after the pedal is released, after shifting gears, or clutch slips during maximum engine loads, such as climbing hills or high vehicle speeds. Clutch slipping is identified by increase in engine RPM without increase in vehicle speed.

Review the Symptoms - Clutch and perform the necessary inspections.

Incorrect clutch pedal height

Adjust the clutch start switch. Refer to Clutch Pedal Position Switch Replacement .

Clutch cable return spring is broken or missing

Replace the spring. Refer to Clutch Return Spring Replacement .

Clutch pedal is binding or sticking

Clear away any items that may be contacting the pedal.

Clutch pedal bushings are seized or worn

Replace or repair the clutch pedal assembly. Refer to Clutch Pedal Replacement .

Clutch housing lever and cross shaft binding

Lubricate the cross shaft and bushings.

Clutch clevis pins or external linkage seized or binding

Lubricate the pins and linkage.

Clutch cable binding or seized

Replace the clutch cable. Refer to Clutch Cable Replacement .

Clutch cable kinked or damaged

Replace the clutch cable. Refer to Clutch Cable Replacement .

Grease or oil contamination of the clutch disc

1. Repair the source of the oil leak.
2. Repair the source of the grease leak.
3. Clean the contamination from the clutch components.
4. If contaminates cannot be removed, replace the clutch assembly. Refer to Clutch Assembly Replacement .

Worn or damaged flywheel

Replace the engine flywheel. Refer to Engine Flywheel Replacement in Engine Mechanical - 8.1L or Engine Flywheel Replacement in Engine Mechanical - 6.6L.

Worn clutch discs facing

Replace the clutch assembly. Refer to Clutch Assembly Replacement .

Burnt or glazed clutch discs

Replace the clutch assembly. Refer to Clutch Assembly Replacement .

Input shaft splines worn

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

Release bearing binding

Clean the release bearing bore and the transmission quill tube.

DEFINITION: The clutch does not engage completely after the pedal is released, after shifting gears, or the clutch slips during maximum engine loads, such as climbing hills or high vehicle speeds. Clutch slipping is identified by increase in engine RPM without increase in vehicle speed.

Review the Symptoms - Clutch and perform the necessary inspections.

Incorrect clutch pedal height

1. Adjust the pedal stops.
2. Adjust the clutch start switch. Refer to Clutch Pedal Position Switch Replacement .

Clutch cable return spring is broken or missing

Replace the spring. Refer to Clutch Return Spring Replacement .

Clutch pedal is binding or sticking

Clear away any items that may be contacting the pedal.

Clutch pedal bushings are seized or worn

Replace or repair the clutch pedal assembly. Refer to Clutch Pedal Replacement .

Clutch housing lever and cross shaft binding

Lubricate the cross shaft and bushings.

Clutch clevis pins or external linkage is seized or binding

Lubricate the pins and linkage.

Clutch cable is binding or seized

Replace the clutch cable. Refer to Clutch Cable Replacement .

Clutch cable is kinked or damaged

Replace the clutch cable. Refer to Clutch Cable Replacement .

Grease or oil contamination of the clutch disc

1. Repair the source of the oil leak.
2. Repair the source of the grease leak.
3. Clean the contamination from the clutch components.
4. If contaminates cannot be removed, replace the clutch assembly. Refer to Clutch Assembly Replacement .

Worn or damaged flywheel

Replace the engine flywheel. Refer to Engine Flywheel Replacement in Engine Mechanical - 8.1 L or refer to the Caterpillar engine service manual.

Worn clutch discs facing

Replace the clutch assembly. Refer to Clutch Assembly Replacement .

Burnt or glazed clutch discs

Replace the clutch assembly. Refer to Clutch Assembly Replacement .

Input shaft splines worn

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