Professional Documents
Culture Documents
This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved.
Chapter
Clutch Problems,
Troubleshooting,
and Service
Technical Terms
125
126 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 127
the clutch assembly or some other major component. you, the technician, to find out what caused the prema- Clutch Drag
Introduction Check the easiest, most obvious solutions (such as ture clutch damage, so the problem might be prevented in
clutch adjustment) before removing the clutch. Also, the future. If the clutch cannot be disengaged or it fails to
look beyond the clutch for possible solutions. Consider As stated, clutch problems can occur as a result of release, you cannot shift gears. In this situation, when you
This chapter explains how to diagnose and service
the possibility the problem is something other than the careless operation. Driving with a foot resting on the stop the vehicle in gear (clutch pedal depressed), the
clutches. Clutch problems and their causes are identified.
clutch. Figure 7-1 shows typical clutch problems. Study clutch pedal is an example. This careless habit, called engine stalls. This condition is known as clutch drag.
Procedures performed with the clutch in place, such as
them carefully. riding the clutch, causes the clutch to slip. As a result, Clutch drag varies in degree. Slight drag when the
clutch adjustment, are covered. Major repair and replace-
Clutch discs are like brake linings: they gradually excess heat is generated and premature wearing of clutch clutch pedal is fully depressed may tend to make the car
ment procedures, which require clutch removal, are also
wear out as they operate. Every time the clutch is engaged friction surfaces occurs. Among the different ways clutches creep when in gear or cause gear clash when the gears are
explained.
or disengaged, some friction material is removed from the are misused, riding the clutch is the most common. It can first engaged. The two most common causes of slight drag
clutch disc. The amount of material lost during each action put the equivalent of 50,000 miles of normal wear on a are improper linkage adjustment and lack of lubrication at
the moving parts of the linkage.
Clutch Problems and is small, and most clutches will last for 50,000 miles
(80,000 km) or more. It is normal for a clutch to wear out
clutch in under 10,000 miles.
Naturally, clutch problems can occur as a result of In some cases, the car creeps during the clutch
Troubleshooting after this mileage is reached. abuse. An example is increasing engine speed and then spindown, wherein the disc continues to spin for several
Often, however, a clutch will not last as long as suddenly releasing the clutch pedal, allowing the pressure seconds after being disengaged. To determine if this is
You cannot properly service a clutch until you 50,000 miles. Like any other mechanical part, the clutch plate apply springs to engage the clutch almost instantly. causing the creeping and not clutch drag, a simple test can
know what is wrong with it. In many instances, a clutch can be damaged by careless or abusive operation. Further, This is often referred to as dumping the clutch, or popping be performed (if the transmission is not fully synchro-
problem that seems to be severe is minor and easily it can be damaged by outside factors—factors that cannot the clutch. It causes instant heat buildup in the clutch disc nized). Depress the clutch pedal, shift into Neutral, and
remedied. In other cases, the solution involves replacing be attributed to the vehicle operator. It is important for facings and places tremendous stress on the clutch and the wait about 30 seconds. Then, shift into an unsynchronized
entire drive train. gear, usually reverse. If the gear engages smoothly, the
Clutches usually do not last very long under this creeping is caused by spindown, which is normal. If the
Clutch disc Loose, broken, or type of abuse. Overheated clutch facings, a result of gear clashes, the creeping is caused by clutch drag.
facing missing clutch cover dumping the clutch, can become glazed within seconds. (Consult Chapter 8 for an explanation on synchronizers.)
worn attaching bolts This form of abuse can also cause flywheel, clutch cover, Clutch drag can be caused by a clutch linkage that is
Clutch pressure or clutch housing attaching bolts to shear off. Further, it loose, disconnected, or inoperable. The clutch fork inside
plate damaged can cause clutch disc hub splines to be stripped or input the clutch housing may be disconnected from the
or worn shafts to break. throwout bearing. A hydraulic linkage may be low on
Engine flywheel fluid—the reservoir may be empty, or the cylinders or lines
friction surface Placing more load on a clutch than it is designed to
handle can also be a source of damage. An example is may be leaking. There might be air in the system. A discon-
warped or damaged
starting off in high, rather than in low, gear. Shifting into a nected linkage or clutch fork or a dry hydraulic system is
Release levers or
higher gear before the engine has reached the proper rpm characterized by a pedal that requires little, if any, effort to
fingers bent or worn
also overloads the clutch, as does attempting to change depress. A spongy pedal is the result of air in a hydraulic
Front bearing gears at very high engine speeds. Another example is over- linkage.
retainer hub loading the vehicle to the point that the clutch must be Another possible cause of clutch drag is misalignment
dry or worn allowed to slip heavily when starting off, just to get the of the transmission or clutch housing. This can happen as
vehicle moving. This is a common problem on vehicles a result of loose bolts or as a result of debris between the
Clutch used for towing. mounting faces. Misalignment can cause the linkage or
fork bent As stated, outside factors can also cause clutch internal clutch parts to stick temporarily. Pedal effort will
damage. Oil leaks from the engine rear main bearing seal be normal or higher than normal.
Leaking front
or from the transmission front bearing retainer seal can Clutch drag can also be caused by a worn or frozen
bearing retainer
seal reach the clutch disc. If the disc gets contaminated with pilot bearing, a sticking or warped clutch disc, or a warped
Leaking rear main
bearing seal Clutch oil, it grabs or chatters when engaged. If enough oil gets on pressure plate or flywheel. A worn disc may become so
pilot the disc, it slips at all times and the disc surfaces soon wear overheated, it welds itself to the pressure plate. When
bearing out from the resulting friction. If the disc becomes com- these defects occur, the clutch linkage is working properly
worn but the engine and transmission remain mechanically
pletely saturated with oil, the surface does not wear out,
but the disc itself becomes useless. connected.
Flywheel attaching bolts One of the most common causes of a dragging clutch
Finally, many clutch problems are due to lack of
stripped or broken Transmission is too much pedal free travel. With excessive free travel,
maintenance or careless service. If the clutch linkage is
input shaft not adjusted and lubricated on schedule, or if the the pressure plate may back off somewhat, but it will still
Clutch release
damage or wear retain contact with the disc when the pedal is pushed to
bearing throwout bearing or clutch hub splines are not properly
dry or worn greased during installation, the moving parts may hang the floor. Always check the clutch linkage adjustment
Bearing collar up or operate slowly. The clutch is subjected to undesir- when indications point to a dragging clutch.
Clutch housing
unlubricated able slippage, shortening its life. Slippage and other
misalignment
problems exhibited in clutch operation are presented in
or damaged
detail in the upcoming paragraphs. Figure 7-2 summa-
Clutch Slippage
Figure 7-1. Note typical problems with the clutch assembly. Some defective parts, such as a leaking engine oil seal, are not part of rizes some common conditions and their causes and Clutch slippage is a condition wherein the full power
the clutch assembly but can cause clutch problems. It is very unusual for only one part of a clutch to wear out. You should usually corrections. of the engine does not reach the transmission. The engine
replace any clutch part that you suspect is bad. (DaimlerChrysler)
128 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 129
Clutch Trouble Diagnosis speeds up, but the vehicle speed does not increase as it that depresses with almost no effort may be a sign of weak
should. The clutch disc is not being gripped firmly, and it clutch apply springs.
Condition Probable Cause Correction slips between the flywheel and pressure plate as the Clutch slippage can be caused by improper clutch
members rotate. linkage adjustment. If the clutch linkage is adjusted to
Fails to Release (Pedal pressed a. Improper linkage adjustment. a. Adjust linkage. where there is no free play and the throwout bearing is
to floor. Shift lever does not move b. Improper pedal travel. b. Trim bumper stop and adjust linkage. applying pressure to the release levers or fingers, the clutch
freely in and out of reverse gear. c. Loose linkage. c. Replace as necessary. Note: In this section, we are referring to will not be fully applied, and it will slip.
d. Faulty pilot bearing. d. Replace bearing. abnormal clutch slippage. For smooth Note that if the clutch fork return spring is discon-
e. Faulty driven disc. e. Replace disc. shifts, some degree of slippage is desir- nected, the pedal will have no free play. However, this
f. Fork off ball stud. f. Install fork onto stud. Lightly lubricate able. The clutch pedal should not be released too condition will not cause slippage. When the clutch pedal
fingers at release bearing. Also lube quickly. A controlled release will permit some
bearing I.D. groove. is released after being applied, the apply springs will fully
slippage. As a result, you will not ruin the clutch or re-engage the clutch. The throwout bearing will ride on the
g. Clutch disc hub binding on clutch gear g. Repair or replace clutch gear
other parts of the drive train. In addition, it makes the release levers or fingers but will not apply pressure on
spline. and/or disc.
h. Clutch disc warped or bent. h. Replace disc (runout should not ride easier on the vehicle occupants. them to cause slippage. Therefore, do not confuse this con-
exceed 0.020″). dition with the lack of free play caused by misadjustment.
i. Loose pivot rings in cover assembly. i. Replace plate and cover assembly.
Clutch slippage begins as a minor problem. At first, it
Slipping a. Improve adjustment (no lash). a. Adjust linkage to spec.
b. Oil soaked driven disc. b. Install new disc and correct leak at its
will occur on initial and hard accelerations. As the Grabbing Clutch
problem progresses, slippage will occur on upshifts, down-
source. shifts, and on any kind of acceleration. Left uncorrected, A grabbing clutch engages with a jerk or shudder no
c. Worn facing or facing torn from disc. c. Replace disc. matter how slowly and carefully it is applied. The effect
slippage only becomes worse. Eventually, the clutch disc
d. Warped pressure plate or flywheel. d. Replace pressure plate or flywheel. may be a series of jerks, which is often described as buck-
becomes so badly worn that there is not enough friction
e. Weak diaphragm spring. e. Replace pressure plate. (Be sure lash
present to move the vehicle. ing. This problem may be severe enough to cause damage
is checked before replacing plate.)
A slipping clutch gets very hot. The extreme heat to universal joints or other drive train parts.
f. Driven plate not seated in. f. Make 30 to 40 normal starts.
CAUTION: Do Not Overheat. damages the contact surfaces of the pressure plate and If you suspect a grabbing clutch, always check the
g. Driven plate overheated. g. Allow to cool–check lash. flywheel, causing them to lose their proper finish. This engine and transmission or transaxle mounts before trou-
happens because the heat changes the chemical makeup bleshooting the clutch. Loose mounts can cause a sensa-
Grabbing or Chattering a. Oil on facing. Burned or glazed facings. a. Install new disc and correct leak. tion similar to a grabbing clutch. Also, make sure all clutch
of the metal, reducing its strength and heat absorption
b. Worn splines on clutch gear. b. Replace transmission clutch gear.
capability. A slipping clutch should be repaired before the housing and transmission bolts are tight.
c. Loose engine mountings. c. Tighten or replace mountings.
pressure plate or flywheel is damaged by excessive heat. A grabbing clutch is usually caused by oil deposits
d. Warped pressure plate or flywheel. d. Replace pressure plate or flywheel.
e. Burned or smeared resin on flywheel e. Sand off if superficial, replace burned A badly slipping clutch is usually too glazed and worn disbursed on the friction facing of the clutch disc or by an
or pressure plate. or heat checked parts. down to be fixed by adjustment. A clutch disc that is too overly hot or glazed facing. Less common causes are worn
glazed cannot develop any driving friction between itself splines on the clutch disc hub flange or transmission input
Rattling-Transmission Click a. Weak retracting springs. a. Replace pressure plate. shaft, a warped clutch disc, or warped pressure plate or
and the flywheel and pressure plate. If the clutch disc is
b. Release fork loose on ball stud or in b. Check ball stud and retainer.
completely worn down, the apply springs will not be able flywheel machined surfaces. Another possible cause is a
bearing groove.
to apply enough pressure to the pressure plate to hold it worn or misaligned clutch fork. This can cause the release
c. Oil in driven plate damper. c. Replace driven disc.
d. Driven plate damper spring failure. d. Replace driven disc. tight against the flywheel. The clutch must be replaced. bearing to become crooked or tip on its shaft. The result is
A clutch disc that is soaked with oil, such as from a an uneven application of pressure on the pressure plate
Throwout Bearing Noise with a. Improper adjustment. No lash. a. Adjust linkage. assembly. The bearing collar may begin to wear because of
leaking rear main bearing seal, will also slip. In this case,
Clutch Fully Engaged b. Release bearing binding on trans- b. Clean, relubricate, check for burrs, the uneven pressure from the fork.
the clutch may not be worn down. If the clutch disc is
mission bearing retainer. nicks, etc.
c. Insufficient tension between clutch c. Replace fork. soaked with oil, however, it must be replaced.
A clutch often slips if the vehicle is driven through
fork spring and ball stud.
deep water. This is because water enters the clutch hous-
Clutch Chatter
d. Fork improperly installed. d. Install properly.
e. Weak linkage return spring. e. Replace spring. ing and soaks the clutch disc. The clutch will usually work Clutch chatter is a specific type of vibration that is
normally after the disc dries. accompanied by a rapid clunking or rattling noise. It
Noisy a. Worn release bearing. a. Replace bearing.
Slippage can also be caused by disc, pressure plate, occurs while the clutch is being engaged, as opposed to
b. Fork off ball stud (heavy clicking). b. Install properly and lubricate fork
fingers at bearing. or flywheel contact surfaces that are warped. If the surface while the clutch is fully engaged. It is closely related to
c. Pilot bearing loose in crankshaft. c. See Section 6 for bearing fits. is not perfectly flat and straight, the flywheel or pressure clutch grabbing. It differs, however, in that it is heard more
plate will not make good contact with the disc. As a result, than it is felt. The actual noise is caused not by the clutch,
Pedal Stays on Floor When a. Bind in linkage or release bearing. a. Lubricate and free up linkage and the disc may slip (or chatter). Warped surfaces may be but by the vibration set up in the clutch linkage and drive
Released release bearing.
caused by improper manufacturing processes or by exces- train. Chatter can be caused by loose or misaligned drive
b. Springs weak in pressure plate. b. Replace pressure plate.
sive heat. train components. For example, the transmission and
c. Springs being over traveled. c. Adjust linkage to get proper lash, be
sure proper pedal stop (bumper) is Sometimes, a clutch slips because the pressure plate clutch housing may be seriously misaligned.
installed. apply springs are weak. Weak springs may have been Often, what seems like clutch chatter is really a worn
installed in the pressure plate assembly originally, or the out constant-velocity joint or other universal joint. Other
Hard Pedal Effort a. Bind in linkage. a. Lubricate and free linkage. assembly may have been intended for a smaller engine or causes of chatter include a misaligned flywheel, a worn pilot
b. Driven plate worn. b. Replace driven plate.
vehicle. The springs may have become weak from over- bearing, or both. It is possible that release levers are
heating, or under normal circumstances, the springs may unevenly adjusted or worn. Sometimes, dust from a worn
Figure 7-2. Clutch diagnosis chart. (General Motors) have become weak because of long usage. A clutch pedal clutch disc facing clogs the disc segments and cause chatter.
130 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 131
If the pedal is very hard to work after a new pressure Locknuts Clutch
plate assembly is installed, the pressure plate apply springs Firewall fork
Bellcrank
may be stronger than necessary. This is very common or bulkhead Adjusting attachment
or relay rod
when a heavy-duty or competition (racing) pressure plate threads
Cable
is installed. Return springs that are too heavy might be
responsible for hard pedal effort. Remember, as you Locknut Clutch
Throwout fork
depress the clutch pedal, you are working against return-
bearing contacts
spring tension.
pressure plate
Cable sheath
assembly Pushrod Bracket
Maximum
pedal
In-Car Clutch Service position
Resistance
Figure 7-8. Adjusting free play in a cable linkage. The end of
the cable is threaded. Loosening the locknuts and moving the
begins cable makes the adjustment.
Clutch service commonly requires the removal of Flats for
Freep
major components, such as the drive shaft assembly, trans- lay wrench
Ruler Pushrod threaded
mission, and clutch assembly. However, certain clutch the clutch is worn out. Note that in many vehicles with self-
through pivot block
problems can be attended to without removing these adjusting clutch systems, the throwout bearing is always in
major components. This type of service is categorized as contact with the release levers or fingers. Such bearings are
Floorboard Figure 7-6. This shows a single-locknut adjuster. The locknut is
in-car service. Clutch repairs that fall into this category are loosened and the pushrod is turned in or out to obtain the proper called constant-duty throwout bearings. With the clutch
clutch adjustment and linkage repair or replacement. free play. pedal fully released, the bearing makes light contact with the
Figure 7-5. Free play can be measured using a ruler. The
Procedures are given in this section. amount of free play should match the manufacturer’s specifica- release levers or fingers. Even so, there is enough slack in the
tions. A general check can be made by observing the pedal cable linkage to give some free play at the pedal.
movement. The throwout bearing first contacts the pressure the proper free play is obtained at the clutch pedal. If the clutch is the manually adjustable type, use a
Retighten the first locknut. Recheck the free play at the ruler to measure the actual amount of free play at the
Clutch Adjustment plate assembly at the point where resistance is first felt when
pressing on the pedal. clutch pedal. As a final check, road test the car to check clutch pedal. Compare the amount against the manufac-
Clutch adjustment involves setting the correct clutch operation. turer’s specifications. If the specs are not available, you
amount of free play in the clutch linkage. Too much free can assume that the free play is between 1″ and 1.5″
play can cause clutch drag, preventing the clutch from Note: A slipping clutch that is badly worn Cable linkage adjustment (25 mm and 38 mm). Also, check that the cable and other
ever fully disengaging. In this case, the power flow is not or damaged cannot be repaired by adjust- The cable linkage uses a cable to connect the clutch linkage work freely and do not bind.
completely cut off from the clutch and the engine could ment. If adjustment does not stop clutch pedal to the clutch fork. Adjustment is made by a threaded If the free play must be adjusted, loosen the locknut
continue to propel the vehicle. Too little free play can slipping, or if enough free play cannot be obtained section, which passes through a bracket. This section is holding the threaded portion of the cable sheath. There are
cause the clutch to slip. In this case, the throwout bearing (indicating worn parts), the clutch assembly must be located on the end of the cable linkage at the clutch fork. usually two locknuts holding the end of the cable to a
rotates continually as it contacts the rotating pressure plate removed and worn parts must be replaced. See Figure 7-8. bracket. Leave the locknuts loose and alternately turn them
release levers or fingers, and it quickly wears out. With Some cables are self-adjusting. If there is no free play on until the cable length is correct. Tighten the locknuts and
enough pressure on the levers or fingers, the clutch slips, a self-adjusting clutch, the adjustment mechanism is faulty or recheck the free play at the clutch pedal. Then, road test
overheats, and becomes damaged. the car and check clutch operation.
No matter what type of clutch linkage is used, the free Rod-and-lever linkage adjustment
play can be checked by pushing the clutch pedal with your A rod-and-lever linkage is a series of links, levers, and Bellcrank Hydraulic linkage adjustment
hand. Refer to Figure 7-5 and the next few paragraphs for rods connecting the clutch pedal to the clutch fork. or relay rod
The hydraulic linkage uses hydraulic pressure to
the proper procedure. Adjustment is usually provided by a threaded rod that transfer pedal movement to the clutch fork. As with the
Begin with the pedal in a fully released position—that passes through a pivot block, Figure 7-6 and Figure 7-7. Locknuts previous adjusters, adjustment is made by a threaded
is, with the pedal all the way up. Start pushing down on An adjustment device is located on the linkage at the section on the linkage at the clutch fork. Adjustment to this
Clutch
the pedal. The pedal should move easily for about 1″ clutch fork. linkage changes the effective length of the pushrod at the
fork
(25 mm). In this span, the only pressure you are working To adjust a rod-and-lever linkage, measure the actual slave cylinder. See Figure 7-9.
against is that of the return springs. Past this point, the amount of free play at the clutch pedal and compare it to
pedal becomes harder to push. This is where the throwout specifications. Use a ruler to make an accurate measure- Pushrod
bearing contacts the pressure plate release levers or ment. If the specifications are not available, 1″ (25 mm) of
fingers, and you are working against the force of the pres- free play is usually close. Before attempting to make the Hydraulic Threaded Locknut Clutch
sure plate apply springs. line pushrod Adjuster fork
adjustment, check that the linkage is not worn excessively.
The distance that the pedal moved from the fully A loose, sloppy linkage cannot be satisfactorily adjusted.
released position until it became hard to push is the free Next, for the single-locknut adjuster, loosen the lock- Slave
play. All vehicle manufacturers specify the proper nut that holds the threaded rod to the pivot block. Turn the Pushrod can slide cylinder
amount of clutch free play. Free play is adjusted at some rod until the proper free play is obtained at the clutch through pivot block
place on the clutch linkage. On many vehicles, the pedal and then retighten the locknut. For the double-lock- Dust boot
clutch has a self-adjusting feature that automatically nut adjuster, loosen the one locknut, depending on which Figure 7-7. This shows a double-locknut adjuster. One locknut
adjusts free play whenever the clutch pedal is way the adjustment is to be made. Then, turn the other is backed away, the other is turned in the same direction to Figure 7-9. Adjusting free play in a hydraulic linkage. The
depressed. locknut in the same direction, advancing the pushrod until adjust the pushrod length. Note that the pushrod slides through pushrod is often threaded. Shortening or lengthening the rod
the hole in the pivot block. adjusts free play. The pushrod is held by a locknut.
134 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 135
Measure the amount of free play at the clutch pedal. Clutch Clevis pin
Use a ruler to obtain an accurate reading, and compare it linkage rod
against specifications. If the specifications are not avail-
able, between 1″ and 1.5″ (25 mm and 38 mm) of free play
is generally acceptable. Clutch Link
Before adjusting free play, check the master cylinder pedal arm
reservoir to make sure the fluid level is sufficient. Add
Dash
DOT 3 brake fluid if necessary. Bushing
panel
Reservoir 5. Obtain new seals. Make sure they are the correct ones. which may be contaminated, is returned to the system. The Disconnect battery
cap Lubricate them with brake fluid, never with petroleum- method is outlined as follows:
Master cylinder Reservoir based lubricants, and install them on the piston. 1. Open the bleeder valve by loosening it about a
6. Install the piston in the cylinder. Be careful not to quarter or half turn.
Pushrod Snap ring damage the new seals.
Retaining 2. If the bleeder valve has a cap, remove it at this time.
Dust boot clamp 7. Install the retaining snap ring, pushrod, and boot. Attach a hose to the end of the open bleeder valve.
Washer
8. Install the rebuilt cylinder. Place the free end of the hose in a clear container of
9. Attach the hydraulic line. There should be no air in brake fluid.
hydraulic lines; if there is, it must be removed by 3. Fill the system reservoir with fresh brake fluid, and
Piston bleeding the lines. If the hydraulic system was dis- replace the cap.
rear seal assembled for any type of repairs, you must bleed 4. Pump the clutch pedal until bubbles stop coming out
Piston the lines to remove the air. Once the bleeding of the hose in the container. You might want to have
front seal Stem tip
seal operation is finished, pressure on the pedal should an assistant watch for the bubbles for you to make the
Spring Valve apply the clutch firmly. There should be no spongy- job easier.
retainer stem pedal feel. 5. With the clutch pedal released, close the bleeder valve.
Valve stem Return Retainer The slave cylinder has a bleeder valve for bleeding Figure 7-15. The battery should always be disconnected at the
A Piston retainer spring spring ground terminal before beginning any clutch repairs. If the
air from the system. The valve looks like a screw with a
battery is not disconnected, there is always a possibility that
small hole running down its length. The hole is closed the starter will be operated, causing injury. (Subaru)
Bleeder
off when the bleeder valve is tightened down. Loosening Clutch Removal
the valve a few turns will open the hole and permit sys-
Bleeder valve tem bleeding. Note that some bleeder valves have a cap,
valve cap The exact procedure for clutch removal varies
as well. according to the engine and drive train layout. On vehi-
There are two methods to manually bleed air from a cles with rear-wheel drive and on many vehicles with
Spring hydraulic system. One method is preferred over the other Warning: Never work under a vehicle
front-wheel drive, the transmission and clutch are supported only by a hydraulic jack. Always
because it minimizes the chance of fluid contamination. removed from the vehicle without removing the engine.
This preferred method is outlined as follows: support the vehicle with jack stands.
On some front-wheel drive and on most rear-engine
1. Fill the system reservoir with fresh brake fluid. Leave vehicles, the engine, clutch, and transaxle are removed
the cover off the reservoir. (Bleeder valve is closed.) from the vehicle as an assembly. When removed from
Pushrod 3. Once the vehicle is properly raised and supported,
2. If the bleeder valve has a cap, remove it at this time. the car, the components are separated to expose the
clutch assembly. On other front-wheel drive vehicles, remove the drive shaft assembly. (Chapter 13 covers
Attach a hose to the end of the bleeder valve. Place
Seal
the engine and clutch are removed, leaving the this in detail.) Cap the rear of the transmission to pre-
Piston the free end of the hose in a clear container. Fill the
transaxle in the vehicle. On a few vehicles, the clutch vent oil dripping. See Figure 7-16. If the vehicle has
container with enough fluid to cover the bottom of
Snap ring can be removed and replaced without removing any four-wheel or all wheel drive, remove the front drive
Dust cover the hose.
other components. shaft from the transfer case.
B (boot) 3. Have an assistant pump several times on the clutch
pedal. Then, ask the assistant to hold the pedal down. The following sections contain some general proce-
Figure 7-14. Study the exploded views of master and slave dures for removing a clutch from a vehicle. Always refer to Warning: If the vehicle has been operated
4. Open the bleeder valve by loosening it about a quarter the appropriate service information for specific procedures.
cylinders. A—A master cylinder is shown. The shape, the recently, the engine and exhaust system
included parts, and their layout can vary. The manufacturer’s or half turn. Make sure your assistant continues to
will be hot. Always be careful when working
service manual should be consulted for an exact breakdown of keep his or her foot on the clutch pedal. The pedal
on a hot engine.
parts. B—A slave cylinder is shown. It, too, can vary as to parts, will probably go all the way to the floor. Air, or a mix-
shape, and layout. (DaimlerChrysler, General Motors) ture of air and brake fluid, will come out of the bleeder Front-Engine, Rear-Wheel Drive
valve. Keep the outlet of the hose submerged in the The following procedure details the proper way to 4. Disconnect the pushrod or cable and return spring
fluid as it begins to fill the container. Watch for air remove a clutch from a front-engine, rear-wheel drive vehicle: connected to the clutch fork.
bubbles.
3. Once the piston is out, inspect the cylinder for wear 1. Disconnect the battery negative cable, Figure 7-15. 5. Remove the transmission. (Chapter 9 covers trans-
5. Close the bleeder valve once the flow stops. mission removal in detail.) On many vehicles, the
or pitting. If the cylinder bore is worn or pitted, the
cylinder must be replaced. Remove the old seals from 6. Let up on the clutch pedal. clutch housing and transmission case are com-
the piston and discard them. Thoroughly clean all 7. Repeat the process until only brake fluid comes out of Warning: Always disconnect the battery bined in a single casting. In such cases, the clutch
parts and allow them to dry. the bleeder valve. This can be noted by watching the ground cable before working near the housing is removed along with the transmission by
air bubbles emerging from the hose as the system is clutch. Otherwise, if the starter is acciden- removing the unit from the back of the engine.
bled. tally operated, you could be severely injured. Note that the transmission input shaft and front
Caution: Do not allow any petroleum-based 8. Top off the system reservoir with fresh brake fluid, and bearing retainer are removed with the transmission.
solvent to remain on the cylinder or piston. put the cover back on the reservoir. Do not reuse fluid In addition, the clutch fork and throwout bearing
bled from the system, as it may be contaminated. 2. Raise the vehicle with an approved hoist or hydraulic assembly are removed with the one-piece, or integral-
jack. If using a hydraulic jack, be sure to install good type, casting. If the vehicle has a transfer case, the
There is an alternative method of bleeding air from a
4. Install the return spring, when there is one, in the quality jack stands under the vehicle frame before transmission and transfer case can be removed as
hydraulic system. It can be done without an assistant and
cylinder. getting under the vehicle. a unit.
without wasting brake fluid; however, expelled fluid,
138 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 139
Punch marks
Transmission
Clutch
A Rear axle housing
Transmission housing
jack
the axles. On other vehicles, the drive axles can be to the clutch disc splines or transmission input shaft. or damage. Some technicians will automatically replace Another way to remove the old pilot bearing is to
removed without removing these parts. (This is Make sure, for this and other safety reasons, that you the bearing as a matter of practice. If there is any doubt pack the recess behind the bearing with heavy grease.
covered in detail in Chapter 15.) support the transaxle at all times. If a transaxle were about a pilot bearing’s condition, it should be replaced! Then, install a driver into the pilot bearing—an old input
to fall, it could cause injury or damage. Roller- or ball-type pilot bearings should be inspected shaft works nicely. Put on eye protection and strike the
Warning: If the vehicle has been operated From here, the clutch removal procedure duplicates for lack of lubrication. To check this, turn the bearing and exposed end of the input shaft with a hammer. The force
recently, the engine and exhaust system that for front-engine, rear-wheel drive vehicles. To com- feel for roughness. If it does not turn smoothly, it should be from the hammer will travel through the input shaft to the
will be hot. Always be careful when work- plete clutch removal, continue with step 6 of that section. replaced. grease. The grease will push the bearing from the crank-
ing on a hot engine. In a pilot bushing, wear will show up as looseness shaft. See Figure 7-22.
between the bushing and the input shaft pilot. A good way
to check for looseness is to insert a used input shaft into the Bearing installation
4. Disconnect the pushrod or cable and return spring Clutch Parts Inspection and Repair bearing and try to wiggle it. If it has too much play, the Before installing the new pilot bearing, slip it over the
connected to the clutch fork. bushing is worn out and it should be replaced. pilot of the transmission input shaft. This is done to ensure
With the clutch removed, each component must be
5. Remove the transaxle. (This is covered in detail in it is the proper bearing. If it will not slip over the shaft, or
carefully inspected for wear and damage. Be sure all parts
Chapter 11.) On many vehicles, the transaxle and if the fit is too loose, it is not the correct bearing.
are clean before inspection. Clean the flywheel face and Note: To perform this check, you must have
clutch housings are a single unit, Figure 7-20. If this is The next step is to drive the new bearing into the
pressure plate with a nonpetroleum-based cleaner. Do not the same type of input shaft as used in the
the case, the complete unit is removed from the crankshaft bore, Figure 7-23. Use a properly sized driver to
wash the throwout bearing in any kind of solvent. Do not vehicle transmission.
engine. On vehicles requiring the engine also be avoid damage. Measure the installed depth of the pilot
get grease on the clutch disc facings.
removed for clutch replacement, refer to the manu- bearing. If this depth is too shallow, the input shaft may
facturer’s service manual. Look for any signs of damage or wear, no matter how
contact the bearing. This will damage the bearing, the
slight. After the defect is identified, the concerned part(s)
Note that the transmission input shaft and front bearing Bearing removal input shaft, or both. If the bearing is driven in too deeply,
may be repaired or replaced. Service procedures for the var-
retainer will be removed along with the transaxle. In addi- it may not make full contact with the input shaft pilot. This
ious related parts of the clutch are the focus of this section. There are a couple ways to remove a pilot bearing.
tion, the clutch fork and throwout bearing assembly will is not a problem with bushings, as they are usually longer.
One way is to use a pilot bearing puller tool, as shown in
be removed with the one-piece, or integral-type, casting. If bushings are driven in too deeply, there is still usually
Figure 7-21. One variation of this tool is the threaded-tip
Pilot Bearing Service puller. The threaded-tip puller is used to remove a pilot
adequate surface contact with the input shaft pilot.
Once the pilot bearing is properly installed, lubricate
A worn pilot bearing will allow the transmission input bushing, but it ruins the bearing in the process. The center
Warning: Support the engine with an it with a small quantity of high-temperature grease. Most
shaft and clutch disc to wobble. This can cause clutch shaft, or pilot, of this tool has a self-tapping tip. The pilot is
engine holding fixture when removing the bearings have a recess behind the bearing. A small amount
vibration, a noisy clutch, and damage to the transmission. threaded into the bore of the bearing. When fully inserted,
transaxle. This will keep the engine from of grease stored in this recess will find its way to the bear-
Pilot bearings are relatively cheap, and they are easy to the legs of the puller are adjusted to seat on the crankshaft
dropping as you remove the transaxle and will ing surface, helping to keep it supplied with lubricant. See
change while the clutch is being serviced. flange. As the tool is tightened further, it pulls the pilot
protect the motor mounts. Figure 7-24.
bearing from the crankshaft bore. Another variation, called
an expandable finger-tip puller, is a similar tool used when
Bearing inspection
Also, use a transmission jack to support the transaxle. ball or roller bearings are used.
The clutch pilot bearing is not serviced until the
Never let the transaxle hang unsupported once clutch is removed. The bearing is often worn out by then.
attaching bolts connecting the transaxle and clutch The pilot bearing should be inspected for excessive wear Engine
housings are removed. This action can cause damage crankshaft
flange Bushing forced
Special puller
out by grease
Flywheel Hammer
blows
Friction disc
Pressure plate
assembly Old input
Clutch release bearing shaft
Engine Transaxle with
Grease builds Heavy grease
integral clutch
housing pressure on packed inside
rear of pilot bore
bushing
Flywheel Pilot bearing Figure 7-22. A pilot bearing can also be removed by packing
grease into the recess behind the bearing. A driver is then
Figure 7-21. The pilot bearing removal tool will make pilot bear- placed into the pilot hole and struck. The driver moves into the
ing removal easier. (DaimlerChrysler) grease, creating pressure. The pressure drives out the bearing.
Figure 7-20. The clutch housing and transaxle case are usually combined into a single casting. (General Motors)
142 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 143
without machining. If the flywheel is not badly worn, it can repeat this procedure at least three more times at different Flywheel repair
Crankshaft be cleaned by light sanding. positions on the flywheel. If any of the samples produce Some flywheels may be damaged beyond repair.
flange fluctuations exceeding 0.01″ (0.25 mm), the flywheel must Others may be repaired and then reinstalled. Some of
Flywheel inspection be resurfaced. these may be fixed by replacing the ring gear or by
As mentioned, the surface of the flywheel should also resurfacing.
Clutch pilot Visually inspect the flywheel for obvious signs of dam-
be checked for runout. This is a condition of a rotating Flywheels with damaged ring gears are usually
bearing age. Check the flywheel machined surface for discoloration
object, such as a shaft or flywheel, in which the surface is replaced. Some ring gears can be removed from the fly-
(caused by overheating), scoring, or extremely shiny sur-
not rotating in a true circle or plane. Radial runout is a wheel and replaced, Figure 7-26.
faces. In some cases, the flywheel may have deep heat
measure of out-of-roundness. It is measured at right angles
cracks. Look for warping. Inspect the threads in the holes
to the centerline of an object. Excessive radial runout may
for the clutch cover attaching bolts. If they are stripped,
be caused, for example, by a bent shaft. Lateral runout is Flywheel
they can be restored by installing a thread repair insert.
a measure of in-and-out movement, or wobble. It is mea-
Driving tool Also, check the flywheel ring gear for damage. If even one
sured in the direction that is lengthwise to the centerline of
ring gear tooth is broken, the ring gear must be replaced.
the rotating object. In other words, it is measured on the
Note that if the ring gear teeth are damaged, you should
plane surface of the rotating object. Excessive lateral
also check the teeth of the starter drive pinion for damage.
runout can result, for example, if a flywheel is not mounted
Figure 7-23. A new pilot bearing should be installed with the If the flywheel is not obviously damaged, use a
proper bearing driver. Use a driver that contacts the outer race only properly.
straightedge and feeler gauge to check for warped contact Use chisel to
when driving a roller- or ball-type pilot bearing. Always be very To check for lateral runout, slowly rotate the flywheel
surfaces. Manufacturers’ specifications as to maximum split and remove
careful to avoid damage when installing a new bearing. (Ford) while watching the dial indicator. Determine the lowest ring gear
warpage vary. As a general rule, if more than a 0.01″
point on the flywheel, which corresponds to the lowest
(0.25 mm) feeler gauge fits under the straightedge, the A
reading on the dial. Zero the indicator at this point. Move
flywheel must be resurfaced.
the flywheel until the highest reading is recorded. This
Caution: Do not put too much lubricant on A dial indicator also can be used to check for a warped
measurement is the lateral runout.
the bearing or in the recess. Excess lubri- flywheel. In addition, it can be used to check the flywheel
Lateral runout should not exceed the manufacturer’s
cant will be thrown out of the pilot bearing runout. Push the flywheel toward the engine to remove Torch
specifications. If it does, the flywheel may not be mounted
and can ruin the clutch disc. Note that some bearings crankshaft endplay. Then, mount the dial indicator on a
properly. Remove it and check for burrs between the fly-
are prelubricated and do not require any additional stationary part of the engine with the indicator point bearing
wheel and the face of the crankshaft flange. If no burrs
lubrication. on a smooth, relatively undamaged part of the machined fly-
exist, check the runout of the crankshaft flange.
wheel surface, as shown in Figure 7-25. Rotate the flywheel
Note that while the dial indicator is mounted, you can
and watch the dial to determine how much fluctuation in val-
Flywheel Service ues there seems to be, which would give an indication of also measure crankshaft endplay. Push the flywheel for- Heat new ring
ward and rearward and note the displacement on the dial. gear to expand and
The flywheel is large and very heavy, and removing it warping. If, rather than a series of fluctuations, the dial shows
a steady increase for half a turn and then a steady decrease, ease installation
can be difficult and even dangerous. It should not be
removed unless it is in need of resurfacing. It is rare to find flywheel runout may be excessive. In either case, the fly- Flywheel removal
a flywheel that is not showing some sign of wear or over- wheel must be removed and resurfaced or repositioned.
The easiest way to remove the flywheel attaching
heating. Judgment is called for in deciding if it must be To check warpage, zero the dial indicator; then, slowly
bolts is with an impact wrench. If you do not have an
resurfaced. In many cases, the flywheel can be reused turn the flywheel through about a quarter of a revolution.
impact wrench to remove the flywheel, it must be kept
Watch the indicator face and note if displacement ever B
from rotating so the attaching bolts can be loosened. While
exceeds 0.01″ (0.25 mm). Without moving the indicator,
Crankshaft the bolts are being removed, the flywheel can be held in
Lightly place using a flywheel turner or locked in place with a fly-
grease recess wheel holder; alternatively, a block of wood can be placed
Pilot
bearing between the flywheel and a stationary part of the engine.
Flywheel
surface
Warning: Always wear eye protection when
using an impact wrench.
Dial
indicator A flywheel is very heavy. It can cause injury or severe
damage if dropped. Do not remove the bolts completely C
until you have the flywheel secured so that it cannot fall.
Once the flywheel is securely held, the bolts can be Figure 7-26. Most manual transmission flywheels have a
Pilot bearing to removable ring gear. A—A chisel is being used to remove the
Read while loosened and the flywheel can be removed. Sometimes there
be installed to ring gear from a flywheel. Be careful not to damage the
rotating crankshaft is a flat metal spacer between the flywheel and the crankshaft
spec distance flywheel. B—You should heat the replacement ring gear with a
flange. The spacer should be saved for reassembly. torch or in an oven. Be careful not to overheat the ring gear, or
Figure 7-25. Proper mounting of the dial indicator is important.
After removing the flywheel, check the rear main the metal will lose its strength. C—Place the new ring gear over
Figure 7-24. Grease the recess behind the pilot bearing, but be The base must be solidly attached to the rear of the engine.
careful to use only a small amount. Lack of grease will allow the Push on the flywheel to remove crankshaft endplay. Position
bearing seal for leaks. If the seal is leaking, oil could reach the flywheel and ensure that it is properly seated. Always wear
bearing to run dry and be damaged. On the other hand, too indicator so that plunger just touches the flywheel. The dial is the new clutch disc and ruin it, just as it may have ruined gloves or use tongs to prevent burning your hands when
much grease will drip out and damage the clutch disc. (Ford) then zeroed. (Ford) the old disc. A leaking seal must be replaced. handling the hot ring gear. (General Motors)
144 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 145
A—Burned disc facing—Oil contamination, slipping clutch, B—Hub splines worn—Improper engine-to-transmission align- A—Chatter marks on pressure plate—Oil or grease contamination, B—Broken pressure plate retracting spring—Normal fatigue,
insufficient clearance adjustment. ment, damaged input shaft, bad pilot bearing. binding linkage, loose or soft motor mounts, worn driveline parts. wrong clutch for vehicle, low-quality pressure plate.
C—Worn disc facing—Weak pressure plate springs, normal D—Damaged hub splines—Transmission drawn into place with C—Pressure plate hot spots or heat checks—Clutch slippage, D—Broken release levers—No free play in clutch adjustment,
wear, scored or cracked flywheel. bellhousing bolts. oil or grease contamination, clutch adjustment too tight, binding bad release bearing, improper part alignment.
linkage, driving habits.
E—Scored disc facing—Flywheel not machined when needed, F—Wear on hub—Installed backwards, wrong parts.
E—Scored pressure plate—Clutch disc worn to rivets, adjust- F—Broken diaphragm spring—Installation error, excessive
bad pressure plate reused.
ment too tight, clutch slippage, binding linkage. pedal reserve causing throwout bearing to travel too far during
disengagement.
Figure 7-29. Study the types of clutch disc damage. (Luk)
Figure 7-30. Study the types of pressure plate assembly damage. (Luk)
148 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 149
Pressure plate assembly repair the bearing must be reused, it should be carefully checked 9 springs painted light Cover
Most repair shops choose to completely replace pres- for defects. 3 springs unpainted blue adjacent to levers
sure plate assemblies, rather than rebuild them. It is possi-
ble, however, with the proper equipment, to take apart a Caution: If you intend to reuse a throwout
pressure plate assembly and replace just the parts that are bearing, do not wash it in any kind of clean-
worn. This is typically done on an assembly line by large ing solvent. Solvent will dissolve the Springs
automotive rebuilders. As a general rule, pressure plate throwout bearing lubricant, which cannot be replaced. and levers
assemblies that are put together with nuts and bolts can be in position
rebuilt, while pressure plates held by rivets cannot be
rebuilt. If a shop decides to rebuild a pressure plate assem- 9 springs
bly, it must closely follow the manufacturer’s directions. A Throwout bearing assembly inspection painted orange
3 springs
painted
general procedure for rebuilding a pressure plate assembly Check the throwout bearing for roughness by attempt- adjacent to levers
light gray
is shown in Figure 7-31. Remember to wear eye protection! ing to rotate it by hand. If rotation is rough, or if it appears
to have lost its grease, it should be replaced.
E—To reassemble, install the release levers and apply springs. New or
Check the bearing collar for a free (but not loose) fit
Throwout Bearing Assembly Service on the hub of the transmission’s front bearing retainer. A
Basically, install the release levers by reversing the procedure resurfaced
for removal. If new springs are used, install them using the pressure plate
The throwout bearing is almost always replaced when loose fit indicates that the collar or hub, or both, is worn. sequence shown; otherwise, return the springs to their original
the clutch is serviced. It is often a source of problems. If Check the collar where it contacts the clutch fork. If the positions. F—With the pressure plate assembly positioned on the arbor
press as per original setup, slowly apply pressure to the clutch
Pressure cover. The drive-lug openings in the clutch cover should fit over
plate the drive lugs; apply springs should fit into their seats, as
shown. Screw the eyebolt adjustment nuts onto the eyebolts
until their tops are flush. Slowly release the arbor press and
Arbor remove the assembly.
press Cover Height gauge
Gauge
12″ Eyebolt
Clutch plate
cover J-6456-01 adjustment
nut
Remove Remove Gauge
Block adjustment nuts springs plate
A—Use an arbor press to compress pressure plate apply B—Carefully mark positions of all springs and release levers.
springs so that the assembly can be taken apart. Place and This will ensure parts are reinstalled in their original positions.
arrange the block under the pressure plate so that the cover is Organize the disassembled parts of the pressure plate assem- Spare
free to move down. Remove the eyebolt adjustment nuts, which bly on the workbench. Replace all parts that show wear. flywheel
are used to adjust the release lever height, from clutch cover. H—Position the height gauge on the hub of gauge plate. Turn
Slowly release the arbor press so the cover can be removed G—To ensure uniform clutch application, the release levers the eyebolt adjustment nut until the lever is flush with the height
without the apply springs flying out. must be set to equal heights. Place the gauge plate on the gauge. Adjust all levers in this manner. Stake all adjustment
spare flywheel, and place the pressure plate assembly over it. nuts when finished so they will not loosen in service. A straight-
The gauge plate occupies the position normally occupied by edge can also be used and placed across the cover. Levers can
Eyebolt Drive lug
the clutch disc and simulates installed component positions. then be set to a height at some specified distance down from
Bolt the clutch cover to the flywheel. Note that spacers or shims the straightedge. Remove the clutch cover from the flywheel,
may be used instead of gauge plate. loosening the bolts gradually until spring pressure is relieved.
Release
lever Figure 7-31. Continued
collar is worn, the fork usually is worn also. Any worn Replacement bearings must be pressed onto the col-
parts should be replaced. Figure 7-32 shows damage lar after the old bearing is removed. To remove the
related to the throwout bearing, which you might find throwout bearing, press it from the collar using a bench
during inspection, along with possible reasons the damage vise or press. Adapters may be necessary to properly per-
occurred. form the pressing operation. Press on the new throwout
Strut
bearing. It should be fully seated on the shoulder of the
C—Remove release levers. To do this, lift up on the lever and Throwout bearing assembly repair bearing collar when complete. Refer to Figure 7-33.
D—Grease the pressure plate drive lugs with high temperature
remove the strut. Keep all parts of each particular lever grease, after inspecting assembly for cracking, wear, and other Some throwout bearings are an integral part of the
together. damage. bearing collar. These are replaced as a unit. Many Caution: Do not apply driving force through
throwout bearings, however, are a press fit onto the bear- the bearing elements when installing the
Figure 7-31. Procedures A through H illustrate the steps in a coil-spring pressure plate assembly overhaul. This procedure is ing collar. The assembly can be repaired by replacing the
general, and the manufacturer’s service manual should always be consulted. (General Motors) (continued) throwout bearing.
bearing or collar—whichever is in need of repair.
150 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 151
Flywheel Tighten to Move fork surfaces are flush. This will keep the transmission occurs when the clutch is engaged but does not transmit
holding tool specs with from hanging and damaging the clutch hub splines all of the engine power. Slippage can be caused by a worn-
torque wrench or the input shaft. out clutch, improper linkage adjustments, or oil on the
Input shaft
clutch facings. Less common causes are a warped
6 flywheel, clutch disc, or pressure plate, or worn pressure
1 Caution: Do not use the bellhousing or
plate apply springs. A slipping clutch should be fixed
4 transmission case attaching bolts to try to
before excess heat ruins other clutch parts.
draw in a binding transmission. This could
Clutch vibration can be caused by loose or unbal-
bend the clutch disc hub or break the bellhousing or
Check anced clutch parts. Loose parts usually also cause noise.
transmission case ears. Also, the transmission input
for free Sometimes, what appears to be a clutch vibration is caused
3
movement
shaft could damage the pilot bearing. If the clutch
by loose engine mounts, loose clutch mounting bolts, or
and pilot bearing are installed correctly, the trans-
excessive crankshaft endplay.
mission should slide fully into place by hand.
5 Tighten Clutch noises are often caused by defective bearings.
in crisscross The defective bearing can be isolated by operating the
Pilot tool pattern in steps Clutch clutch pedal. Depending on clutch pedal position, the
8. Reconnect the pushrod or cable and return spring
fork Bearing pilot bearing, throwout bearing, or transmission front
Figure 7-36. The clutch cover attaching bolts should be turned
connected to the clutch fork. Then, adjust, repair, or
retaining bearing can be at fault. Rattles and knocking noises are
down gradually in a crisscross pattern. Push up lightly on the clip replace the linkage as outlined earlier in this chapter.
Install any other parts, such as the speedometer cable, almost always caused by loose parts.
pilot shaft during tightening. This will ensure the disc holds its
alignment. Bolts should be torqued to specifications. Once the shift linkage, or connector wires. Clutch grabbing is usually caused by oil on the clutch
bolts are tight, remove the alignment tool. Try sliding it in and facings. Other possible causes are glazed clutch facings or
9. Reinstall the rear drive shaft assembly as detailed in
out a few times to see that it does not bind. If it does, the trans- wear and misalignment of the throwout bearing assembly
Chapter 13. If the vehicle has a front drive shaft, install
mission will be difficult to install. (Toyota) Figure 7-38. In this design, the bellhousing is an integral part of or clutch fork.
it now. After the drive shaft or shafts are installed,
the transmission housing. The throwout bearing is placed on the Clutch chatter is similar to grabbing, but it is heard
ensure all other drive train connections are made.
front bearing retainer hub. The clutch fork is installed, and then, more than felt. It can be caused by some of the same
the bearing is secured to the clutch fork. Once assembled, the 10. Check the transmission lubricant and add fluid, if defects that cause grabbing. Sometimes chatter is caused
5. Pack the inside of the throwout bearing collar with
clutch fork and bearing are checked for smooth operation. Note necessary. Reconnect the battery negative cable. by a buildup of clutch dust on the friction facings.
high-temperature grease. Typically, collars have an
how the bearing attaches to the clutch fork in this design Lower the vehicle and perform a road test. During the A pedal that is hard to push may be caused by a
outer groove for the clutch fork. The groove should be
variation. (DaimlerChrysler) road test, make sure there is no slippage, the clutch binding condition in the linkage or a throwout bearing that
lightly coated with grease. Refer to Figure 7-37.
engages and disengages smoothly, and the free play is is sticking on the front bearing retainer hub. A new
Install the throwout bearing assembly on the fork. Use correct. Operate the clutch at least 25 times to pressure plate assembly with excessively stiff springs may
clips or retaining springs to secure the bearing to the housing attaching bolts, make sure wires or other properly seat the clutch mating surfaces. Do not over- have been installed.
fork. In cases where the clutch and transmission vehicle components do not get pinched between the heat the clutch during this time. A clutch that does not release may have a defect in
housings are one, it will be necessary to slide the housing and the engine block. Tighten the bolts in a the linkage. Rod-and-lever linkages or cable linkages may
bearing assembly onto the hub of the front bearing crisscross pattern and torque them to the manufac- be broken or disconnected. A hydraulic linkage may be
retainer first. See Figure 7-38. turer’s specifications. Front-Engine, Front-Wheel Drive out of fluid. If the linkage checks out, the problem is inside
6. If the clutch housing was removed, install it now. 7. Using a transmission jack, install the transmission as With a few exceptions, the general clutch installation the clutch assembly. In some cases, the clutch disc may
(A clutch housing that is integral with the transmission outlined in Chapter 9, sliding the input shaft into procedure for front-engine, front-wheel drive vehicles have welded itself to the flywheel or pressure plate.
case is installed with the transmission.) Before instal- engagement with the throwout bearing (where clutch duplicates clutch installation for front-engine, rear-wheel All types of clutch linkage have some provision for
lation, check for dirt or paint that could throw the housing is separate), clutch disc splines, and pilot drive vehicles. Drive axles are replaced instead of the drive adjusting the free play. Free play is measured at the clutch
housing out of alignment. As you tighten the clutch bearing. To align the input shaft and clutch disc shaft assembly. Reinstalling the several variations of front pedal. The usual free play measurement is between 1″ and
splines, use the transmission output shaft to turn the drive axles is covered in detail in Chapter 15. Also, in the 1.5″ (25 mm and 38 mm).
input shaft. It may be necessary to slightly shift or previous section, substitute references to the transmission The clutch linkage may need lubrication or repair.
Coat this groove wiggle the transmission to get the input shaft through with transaxle. Installing the transaxle is covered in detail Rod-and-lever linkages may require new bushings or
Throwout the clutch disc and into the pilot bearing. If the pilot in Chapter 11. On vehicles requiring that the engine also realignment of linkage parts. Cable linkages may have
bearing shaft was used properly, the input shaft should enter be removed for clutch replacement, refer to the manufac- problems due to a corroded or kinked cable. The cable
the clutch assembly without too much difficulty. turer’s service manual. must usually be replaced.
Hydraulic linkages can leak, or the hydraulic lines
can be kinked or swelled shut. Leaks can be spotted by a
Caution: If the transmission shows any
visual examination.
sign of oil leakage through the front
bearing retainer, correct the leak before
Summary Master and slave cylinders can be rebuilt if necessary.
After rebuilding, or whenever the hydraulic system has
installing the transmission.
Clutches can develop problems for many reasons. It been opened, air must be removed from the system. The
is normal for a clutch to wear out after 50,000 miles process of removing air is called bleeding.
Pack this recess Collar (80,000 km). If a clutch wears out sooner, there may be To remove the clutch from a vehicle, other compo-
If the clutch housing is part of the transmission, bolt
the unit to the back of the engine. If the clutch hous- another problem that caused premature clutch failure. The nents must be removed. In most cases, the drive shaft
Figure 7-37. If the throwout bearing is not lubricated properly,
ing is separate, bolt the transmission case to the most common cause of early clutch failure is driver abuse. assembly or drive axles must be disconnected from the
it will bind on the hub of the transmission’s front bearing
retainer, or it will wear rapidly. Apply the proper type of grease housing. Start the attaching bolts as soon as the Clutch problems can be divided into different groups. vehicle. The transmission and clutch housing are then
to the places shown. (DaimlerChrysler) input shaft is slid into place and the mating housing The most common clutch problem is slippage. Slippage removed to reach the clutch assembly.
154 Manual Drive Trains and Axles Chapter 7 Clutch Problems, Troubleshooting, and Service 155
To remove the clutch assembly, the clutch cover 3. Vibration that occurs when the clutch is being 4. Each of the following can cause clutch slippage 11. A pilot shaft is used to align the pilot bearing and the
attaching bolts are removed from the flywheel. Then, the engaged or disengaged is called _____. except: _____.
pressure plate assembly and clutch disc are removed from 4. A deep knocking noise that is similar to an engine (A) excessive pressure plate apply spring pressure. (A) pressure plate
the flywheel. main or rod bearing knock is an indication of _____. (B) warped flywheel or pressure plate surfaces. (B) clutch disc
The flywheel and pilot bearing should be checked for (A) defective bearings (C) worn clutch disc. (C) input shaft
defects. A worn or damaged pilot bearing should be (B) a loose clutch fork (D) misadjusted linkage. (D) throwout bearing
replaced. An overheated or warped flywheel can be resur-
(C) weak retracting or cushion springs
faced by a machine shop. The flywheel ring gear teeth 5. Technician A says that clutch grabbing and clutch 12. Technician A says that one should never work under
should be checked for damage. A damaged ring gear can (D) loose flywheel attaching bolts chatter are the same condition. Technician B says that a vehicle that is supported only by a hydraulic jack.
be removed. The replacement ring gear is installed by 5. Clutch adjustment involves _____. clutch vibration or chatter could be caused by broken Technician B says that jack stands should always be
heating it and placing it over the flywheel. (A) resurfacing the flywheel engine or transmission mounts. Who is right? placed under a vehicle that has been raised on a
The clutch disc is almost always replaced during a (B) rebuilding the pressure plate assembly (A) A only. hoist. Who is right?
clutch teardown. The disc can be checked to determine (B) B only. (A) A only.
(C) setting clutch free play
the cause of failure. This may help avoid a similar clutch (C) Both A and B. (B) B only.
failure in the future. (D) All of the above.
(D) Neither A nor B. (C) Both A and B.
Always check the new disc to make sure it is the proper 6. Why should you not let a transmission hang after
(D) Neither A nor B.
replacement. Many clutch problems after overhaul are removing its mounts? 6. If a noise is heard when the clutch pedal is completely
caused by using the improper clutch disc. 7. Briefly cite two methods that may be used to remove released (up position) with the engine running, which 13. Technician A says that pilot bearings should be care-
The pressure plate assembly is usually replaced as a pilot bearing from the crankshaft bore. of the following bearings is probably defective? fully checked once the clutch is removed. Technician
part of a clutch overhaul. Some assemblies can be rebuilt. (A) Engine rear main bearing. B says that the flywheel should not be removed unless
8. The flywheel face and pressure plate should be it is damaged or needs resurfacing. Who is right?
The rebuilding process requires the use of a press. (B) Clutch pilot bearing.
cleaned with a(n) _____ cleaner. (A) A only.
The throwout bearing should be checked for (C) Throwout bearing.
roughness and lack of grease. Always replace a throwout 9. When inspecting a flywheel, what trouble signs (B) B only.
should you look for? (D) Transmission front bearing.
bearing that shows any sign of defects. The throwout (C) Both A and B.
bearing can be pressed from its collar, and a new bearing 10. Briefly summarize typical steps involved in the clutch 7. Technician A says that automatic transmission fluid
(D) Neither A nor B.
can be installed. The clutch fork should be checked for reassembly process for a front-engine, rear-wheel can be used to refill a hydraulic clutch linkage reser-
wear. Worn forks should be replaced. drive vehicle. voir. Technician B says that kinked clutch linkage 14. A flywheel has deep scoring and cracks. Technician A
Clutch housings do not wear out, but they should be cable can be lubricated to restore normal operation. says that any amount of metal can be cut from the
checked for cracks and warping. The housing may contain Who is right? flywheel to fix this condition. Technician B says that
a ball stud for the clutch fork. The stud should be checked (A) A only. the flywheel can be lightly sanded and reused. Who
for wear and replaced if necessary. (B) B only. is right?
When reassembling the clutch, always make sure your ASE-Type Questions—Chapter 7 (C) Both A and B. (A) A only.
hands are free from oil. Oil or grease on the clutch disc will (D) Neither A nor B. (B) B only.
cause grabbing or slippage. A pilot shaft should be used to (C) Both A and B.
1. Each of the following operator actions can cause early 8. Each of the following is caused by improper clutch
ensure the disc hub splines and pilot hole line up closely. If (D) Neither A nor B.
clutch failure except: adjustment except:
proper alignment is not obtained, the transmission will be
(A) riding the clutch pedal. (A) clutch drag. 15. Technician A says that a clutch disc should be reused
difficult to install. The clutch cover attaching bolts should
always be tightened with the pilot shaft in place. (B) disengaging the clutch when decelerating. (B) clutch slippage. unless wear or damage is severe. Technician B says
After the clutch and other drive train parts are (C) dumping the clutch. (C) grabbing clutch. that all replacement clutch parts should be carefully
reinstalled, the clutch pedal free play should be adjusted to (D) overloading the vehicle. compared to the old parts to help ensure they will
(D) throwout bearing wear.
specifications. Road test the vehicle as the final step. work properly. Who is right?
2. Technician A says that light clutch drag can cause 9. Technician A says that a badly slipping clutch usually (A) A only.
gear clashing. Technician B says that clutch disc cannot be fixed by adjusting the linkage. Technician (B) B only.
spindown can be mistaken for clutch drag. Who B says that free play at the clutch pedal should be
Review Questions—Chapter 7 is right? measured before attempting to adjust the clutch link-
(C) Both A and B.
(A) A only. (D) Neither A nor B.
age. Who is right?
Please do not write in this text. Place your answers on (B) B only. (A) A only. 16. Technician A says that a pressure plate must apply
a separate sheet of paper. (C) Both A and B. (B) B only. evenly to prevent clutch grabbing. Technician B says
1. Explain what the phrase riding the clutch means. (D) Neither A nor B. (C) Both A and B. that the throwout bearing should be replaced if it
What effect can it have on the clutch over time? shows any signs of wear or damage. Who is right?
3. Technician A says that some clutch slippage is neces- (D) Neither A nor B.
(A) A only.
2. Which of the following items concerning the phrase sary for smooth shifts. Technician B says that an oil- 10. Opening the slave cylinder bleeder valve while press- (B) B only.
dumping the clutch is not true? soaked clutch disc will slip, even if it is not worn. ing on the clutch pedal will cause the pedal to _____.
(A) Pressure plate apply springs engage gradually. Who is right? (C) Both A and B.
(A) slowly rise
(B) Means increasing engine speed and then suddenly (A) A only. (D) Neither A nor B.
(B) become hard to push
releasing the clutch pedal. (B) B only. (C) go to the floor
(C) Causes instant heat buildup on clutch disc facings (C) Both A and B.
and places tremendous stress on the drive train. (D) lock up
(D) Neither A nor B.
(D) Is a form of clutch abuse.
156 Manual Drive Trains and Axles
17. A car has a slipping clutch. The car will still move, but 19. A clutch makes a grinding sound as the clutch pedal
the engine races when accelerating. Technician A is depressed and the engine is running. Each of the
says to pull the transmission and replace the clutch. following could cause the problem, except:
Technician B says to adjust the clutch linkage first. (A) misadjusted clutch linkage.
Who is right? (B) oil or grease on the clutch.
(A) A only. (C) warped clutch disc.
(B) B only. (D) warped pressure plate.
(C) Both A and B.
20. A driver complains that the clutch is not working
(D) Neither A nor B. properly. The car is equipped with a hydraulic link-
18. A car shudders when accelerating from a standstill as age. An inspection shows that the slave cylinder is not
the clutch pedal is released. Technician A says to responding to pedal action. Fluid level is all right.
check for loose, softened, or broken motor mounts. Technician A says to try bleeding the hydraulic system
Technician B says to check the clutch and flywheel first. Technician B says to replace the seals in the
friction surfaces for problems. Who is right? system first. Who is right?
(A) A only. (A) A only.
(B) B only. (B) B only.
(C) Both A and B. (C) Both A and B.
(D) Neither A nor B. (D) Neither A nor B.