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Clutch: Testing and Inspection

INTRODUCTION TO CLUTCH DIAGNOSIS
A defective clutch causes a clutch slippage, resulting in poor torque transmission. The causes for this problem may be a faulty clutch line or disc, or a maladjustment of the clutch pedal.

CLUTCH DIAGNOSIS TROUBLESHOOTING STRATEGY
Use these Steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a clutch fault.
1. Gather information from the customer.
2. Verify that the condition described by the customer exists.
3. Find the malfunction by following the Symptom Chart.
4. Verify malfunction is eliminated.





SYMPTOM CHART

SYMPTOM PROCEDURES
Inspection Procedure 1
Clutch slips

DIAGNOSIS
Step 1. Check insufficient clutch pedal play.
If faulty, adjust it. Then go to Step 7.
If normal, go to Step 2.
Step 2. Check the clutch disc facing for excessive wear.
If faulty, replace it. Then go to Step 7.
If normal, go to Step 3.
Step 3. Check the clutch disc facing for hardening and adhesion of oil.
If faulty, replace it. Then go to Step 7.
If normal, go to Step 4.
Step 4. Check the clutch release fork for catching.
If faulty, repair or replace it. Then go to Step 7.
If normal, go to Step 5.
Step 5. Check the diaphragm spring for weakness and damage.
If faulty, replace it. Then go to Step 7.
If normal, go to Step 6.
Step 6. Check the hydraulic system for clogging.
If faulty, repair or replace it. Then go to Step 7.
Step 7. Check symptoms.
Check that the malfunction is eliminated.

Inspection Procedure 2
Gear shift malfunction

DIAGNOSIS
Step 1. Check the excessive clutch pedal play.
If faulty, adjust it. Then go to Step 9.
If normal, go to Step 2.
Step 2. Check the clutch disc for distortion and excessive oscillation.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 3.
Step 3. Check the clutch cover assembly for wear.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 4.
Step 4. Check the clutch disc spline for wear and corrosion.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 5.
Step 5. Check the clutch disc facing for peeling.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 6.
Step 6. Check the clutch release bearing for wear.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 7.
Step 7. Check the pressure plate and flywheel for damage.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 8.
Step 8. Check the hydraulic system for leakage, air mix and clogging.
If faulty, repair or replace it. Then go to Step 9.
Step 9. Check symptoms.
Check that the malfunction is eliminated.

Inspection Procedure 3
Clutch noise

DIAGNOSIS
Step 1. Check insufficient clutch pedal play.
If faulty, adjust it. Then go to Step 9.
If normal, go to Step 2.
Step 2. Check the clutch cover assembly for improper installation.
If faulty, repair or replace it. Then go to Step 9.
If normal, go to Step 3.
Step 3. Check the clutch disc facing for excessive wear.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 4.
Step 4. Check the clutch release fork for catching.
If faulty, repair or replace it. Then go to Step 9.
If normal, go to Step 5.
Step 5. Check the clutch release bearing for wear.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 6.
Step 6. Check the torsion spring for wear and damage.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 7.
Step 7. Check the pilot bushing for damage.
If faulty, replace it. Then go to Step 9.
If normal, go to Step 8.
Step 8. Check the bearing sleeve sliding surface for insufficient lubrication.
If faulty, repair it. Then go to Step 9.
Step 9. Check symptoms.
Check that the malfunction is eliminated.

Inspection Procedure 4
Clutch pedal feels "heavy"

DIAGNOSIS
Step 1. Check the clutch pedal for insufficient lubrication.
If faulty, repair it. Then go to Step 5.
If normal, go to Step 2.
Step 2. Check the clutch disc spline for insufficient lubrication.
If faulty, repair it. Then go to Step 5.
If normal, go to Step 3.
Step 3. Check the clutch release fork for catching.
If faulty, repair or replace it. Then go to Step 5.
If normal, go to Step 4.
Step 4. Check the insufficient lubrication of bearing sleeve sliding surface.
If faulty, repair it. Then go to Step 5.
Step 5. Check symptoms.
Check that the malfunction is eliminated.

Inspection Procedure 5
Worn or damaged clutch disc facing

DIAGNOSIS
Step 1. Check the clutch disc facing for wear and damage.
If faulty, replace it. Then go to Step 7.
If normal, go to Step 2.
Step 2. Check for oil on the clutch disc facing.
If faulty, replace it. Then go to Step 7.
If normal, go to Step 3.
Step 3. Check the diaphragm spring for uneven height.
If faulty, repair or replace it. Then go to Step 7.
If normal, go to Step 4.
Step 4. Check the torsion spring for weak and damage.
If faulty, replace it. Then go to Step 7.
If normal, go to Step 5.
Step 5. Check the pressure plate and flywheel for damage.
If faulty, replace it. Then go to Step 7.
If normal, go to Step 6.
Step 6. Check the mounting for loosening and damage.
If faulty, tighten or replace it. Then go to Step 7.
Step 7. Check symptoms.
Check that the malfunction is eliminated.

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