CLUTCH
WARNING
WARNING: Exercise care when servicing clutch components. Factory installed clutch discs do not contain
asbestos fibers. Dust and dirt on clutch parts may contain asbestos fibers from aftermarket components.
Breathing excessive concentrations of these fibers can cause serious bodily harm. Wear a respirator during
service and never clean clutch components with compressed air or with a dry brush. Either clean the com-
ponents with water dampened rags or use a vacuum cleaner specifically designed to remove asbestos
fibers and dust. Do not create dust by sanding a clutch discs. Replace the disc if the friction material is
damaged. Dispose of all dust and dirt containing asbestos fibers in sealed bags or containers. This will
minimize exposure to yourself and to others. Follow all recommended safety practices prescribed by the
occupational safety and health administration (OSHA) and the environmental safety agency (EPA), for the
handling and disposal of products containing asbestos. Failure to follow these instructions may result in
personal injury or death.
DIAGNOSIS AND TESTING
CLUTCH
Drive the vehicle at normal speeds. Shift the transmission through all gear ranges and observe clutch action. If the
clutch chatters, grabs, slips or does not release properly, remove and inspect the clutch components. If the problem
is noise or hard shifting, further diagnosis may be needed as the transmission or another driveline component may
be at fault.
NOTE: Vehicles equipped with a Dual Mass Flywheel may produce a rattle when the engine is shut off. This
noise is considered normal.
CLUTCH CONTAMINATION
Fluid contamination is a frequent cause of clutch malfunctions. Oil, water or clutch fluid on the clutch disc and pres-
sure plate surfaces will cause chatter, slip and grab. Inspect components for oil, hydraulic fluid or water/road splash
contamination.
Oil contamination indicates a leak at either the rear main seal or transmission input shaft. Clutch fluid leaks are
usually from damaged slave cylinder push rod seals. Heat buildup caused by slippage between the pressure plate,
disc and flywheel can bake the oil residue onto the components. The glaze-like residue ranges in color from amber
to black.
Road splash contamination is dirt/water entering the clutch housing due to loose bolts, housing cracks. Driving
through deep water puddles can force water/road splash into the housing through such openings.
IMPROPER RELEASE OR CLUTCH ENGAGEMENT
Clutch release or engagement problems are caused by wear or damage clutch components. A visual inspection of
the release components will usually reveal the problem part.
Release problems can result in hard shifting and noise. Look for leaks at the clutch cylinders and interconnecting
line and loose slave cylinder bolts. Also worn/loose release fork, pivot stud, clutch disc, pressure plate or release
bearing.
Engagement problems can result in slip, chatter/shudder and noisy operation. The causes may be clutch disc con-
tamination, wear, distortion or flywheel damage. Visually inspect to determine the actual cause of the problem.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment with the crankshaft and transmission input shaft. Misalignment
caused by excessive runout or warpage of any clutch component will cause grab, chatter and improper clutch
release.
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CLUTCH
KJ