DEFINITION: The clutch does not disengage completely to allow smooth shift operations. It 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, many 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.

Too much free travel between pedal and clutch master cylinder

Adjust pedal stops to remove the free travel.

Clutch master cylinder seized or binding

Repair or replace the clutch master cylinder as required.

Linkage at pedal worn or damaged

Repair or replace the linkage as required.

Air in the clutch hydraulic system

Bleed the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding .

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 the tips of the release yoke that are resting against 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 Assembly Replacement .
3. Inspect the linkage at the clutch actuator cylinder for wear.
4. Repair or replace the worn linkage components. Refer to Clutch Assembly Replacement .
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.

Damaged clutch assembly components

1. Remove the clutch assembly.
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 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 any faulty components.

Faulty pilot bearing

Replace the pilot bearing. Refer to Clutch Assembly Replacement .

Transmission input shaft splines worn or damaged

Replace the transmission input shaft. Refer Transmission Disassemble and Input Shaft Assemble in Manual Transmission - MLD6Q Isuzu or 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 assemble. Refer to Clutch Assembly Replacement .

Flywheel housing to clutch housing excessive misalignment

1. Inspect the housing for being faulty.
2. Replace the housing if it is 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 .