Complaint/Condition | Possible Cause(s) | Correction(s) |
|---|---|---|
Clutch Does Not Release | Pedal travel short. Object interferes with pedal. | Move object. |
Hydraulic system failure. | Follow "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary. | |
Clutch disc hub binding. | Clean hub and shaft, lightly grease shaft with high-temp grease (P/N 21005995) or equivalent, replace if necessary. | |
Clutch disc warped or bent. | Inspect clutch disc and replace if necessary. | |
Pressure plate to flywheel bolts loose. | Torque bolts to specification and verify operation. | |
Pressure plate faulty or damaged. | Inspect pressure plate and replace if necessary. | |
Fork and bearing not assembled correctly. | Install properly. | |
Input shaft splines worn or damaged. | Inspect input shaft, replace if necessary. | |
No Pressure or Very Little Resistance in Clutch Pedal | Hydraulic system failure. | Follow "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary. |
Clutch feels "Spongy" When Depressed | Hydraulic system failure. | Follow "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary. |
Pedal Effort High for Entire Pedal Travel | Hydraulic system failure. | Follow "Clutch Hydraulic System Diagnosis" procedures in this manual and replace if necessary. |
Clutch facing worn. | Replace clutch disc. | |
Release bearing binding. | Inspect release bearing, replace if necessary. | |
Pressure plate damaged or faulty. | Inspect pressure plate, replace if necessary. | |
Pedal bushings dry or worn. | Clean or replace bushing and lubricate with lithium grease. | |
High Clutch Engage Point | Clutch facing worn. | Replace clutch disc. |
Clutch is Slipping | Oil soaked clutch facing. | Identify/seal the source of oil leak, replace clutch disc. |
Clutch facing is torn. | Replace clutch disc. | |
Clutch facing is worn. | Replace clutch disc. | |
Clutch facing burnt or glazed. | Replace clutch disc. | |
Pressure plate to flywheel bolts loose. | Torque bolts to specification and inspect clutch disc, replace if necessary. | |
Pressure plate or flywheel faulty, or damaged. | Inspect components and replace if necessary. | |
Hydraulic system failure. | Follow "Clutch Hydraulic System Diagnostics" procedure in this manual and replace if necessary. | |
Clutch housing cover not adjusted properly. | Follow "Clutch Cover (Pressure Plate) Adjustment" procedure in this service manual. Replace if necessary. | |
Mismatch of clutch and clutch housing cover. | Inspect part number labeled on clutch. | |
Clutch is Grabbing, Chattering, or Shuddering | Mount misadjusted/loose. | Torque bolts to specification and inspect. |
Clutch disc warped or bent. | Replace clutch disc. | |
Clutch disc damper failure. | Replace clutch disc. | |
Pressure plate or flywheel warped, faulty, or damaged. | Inspect components and replace if necessary. | |
Clutch disc hub binding. | Clean hub and shaft, lightly grease shaft with high-temp grease (P/N 21005995) or equivalent, replace if necessary. | |
Light oil or grease on clutch facing. | Identify/seal the source of leak, replace clutch disc. | |
Clutch facing burnt or glazed. | Replace clutch disc. | |
Pressure plate to flywheel bolts loose. | Torque bolts to specification and inspect clutch disc, replace if necessary. | |
Input shaft splines worn or damaged. | Inspect input shaft, replace if necessary. | |
Release bearing binding. | Inspect release bearing, replace if necessary. | |
Clutch is Noisy When Disengaging | Release bearing faulty. | Inspect release bearing, replace if necessary. |
Pedal bushing worn or dry. | Clean or replace and lubricate with lithium grease. | |
No grease on ball stud. | Clean, lubricate with high-temp grease (P/N 21005995) or equivalent, and inspect. | |
Clutch fork stabilizer missing. | Replace stabilizer and inspect. | |
Clutch neutral switch click. | Add foam pad to pedal. | |
Clutch is Noisy When Engaging | Release bearing faulty. | Inspect release bearing, replace if necessary. |
Pedal bushing worn or dry. | Clean or replace and lubricate with lithium grease. | |
No grease on ball stud. | Clean, lubricate with high-temp grease (P/N 21005995) or equivalent, and inspect. | |
Cruise switch misadjusted. | Adjust cruise switch, inspect clutch disc for excessive wear and replace if necessary. | |
Clutch fork stabilizer missing. | Replace stabilizer and inspect. | |
Clutch neutral switch click. | Add foam pad to pedal. | |
Clutch Pedal is Squeaking | Pedal bushing worn or dry. | Clean or replace bushings and lubricate with lithium grease. |
Hydraulic system failure | Follow "Clutch Hydraulic System Diagnosis" procedure in this manual and replace if necessary. | |
Clutch Pedal is Buzzing/Growling | Hydraulic system failure | Follow "Clutch Hydraulic System Diagnosis" procedure in this manual and replace if necessary. |
Pressure plate to flywheel bolts loose. | Torque bolts to specification and inspect clutch disc, replace if necessary. | |
Clutch fork stabilizer missing. | Replace stabilizer and inspect. |
