1. SERVICING CLUTCHES l Chapter 3 l Page 49 l Lab manual l Page 45 l Classroom Manual

2. OBJECTIVES l Diagnose clutch-related problems. l Inspect, adjust, replace clutch linkage. l Inspect, adjust, repair, and replace clutch slave and master cylinders, & lines. l Inspect, adjust, and replace release bearing lever, and pivot. l Inspect and replace pressure plate. Page 49

3. OBJECTIVES l Inspect and replace clutch disc assembly. l Inspect and replace pilot bearing. l Inspect or replace flywheel ring gear. l Inspect block, bellhousing, case surfaces. l Measure flywheel runout, and crank endplay. l Measure clutch housing-to-block runout. l Inspect, replace, align power train mounts. Page 49

4. CLUTCH PROBLEM DIAGNOSIS l The more information you have, the easier it is to properly diagnose it. l Talk to the customer, ask questions. l Road test the vehicle with the customer driving, if possible. l Look for driving habits that cause failure. l Listen carefully to changes in the noise. Page 49

5. TROUBLESHOOTING GUIDE l Noises l Binding l Slippage l Pulsation l Chatter Page 51 to 54

6. CLUTCH SLIPPAGE l Engine speed increases vehicle speed does not. l Slipping is caused by: »Improper adjustment (too tight) »Worn disc »Contamination of the disc (oil) l Adjustment clearance decreases with disc wear. Page 54

7. CLUTCH CHATTER l Clutch chatter is a shaking or shuddering. l Clutch chatter is cause by: »Broken motor mounts »Glazed clutch disc »Worn U-joints »Worn pilot bushing l See page 55

8. OTHER CLUTCH NOISES l Most clutch noises are caused by bearings and bushings. l Bushings squeal or howl. l Bearings grumble or grate. l Misalignment is a common cause of clutch problems. Page 56

9. CLUTCH VIBRATES l Clutch vibration can occur at any clutch position. l Can “feel” the vibration, and sometimes hear it also. Page 57

10. DRAGGING CLUTCH l Dragging results from the clutch not completely disengaging. l Maximum spin down time 5 seconds. l Dragging is caused by: »Warped disc or Pressure plate »Loose disc facing »Incorrect clutch pedal adjustment. Page 57

11. PULSATING CLUTCH PEDAL l Pedal pulsation s a rapid up-and-down movement of the clutch pedal as the clutch engages or disengages. l Pulsating is caused by: »Broken, bent, or warped release levers. »Misaligned bell housing. »Warped pressure plate, disc, or flywheel. Page 57

12. BINDING CLUTCH l Clutch pedal does not operate smoothly. l Possible causes of binding are: »Worn front bearing retainer. »Dirty or worn input shaft splines. »Bent or worn linkage. Page 57

13. MECHANICAL CLUTCH CONTROLS l Worn bushings, bent rods, broken springs, and damaged cotter pins can cause excessive pedal effort when operating the clutch. l Free-play decreases as the clutch disc wears. l Worn linkage makes free-play adjustments inaccurate. Page 58

14. CHAPTER 3 pg 56 C

15. CABLE

16. FREE-PLAY ADJUSTMENT l Free play is the clearance between the clutch release fingers and the release bearing. l Free-play is measured at the pedal. l Free-play is critical to clutch life. l Insure return springs are in place. Page 59

17. SELF ADJUSTING Pg 57 C+

18. HYDRAULIC CLUTCH CONTROLS l Hydraulic clutch components are serviced like hydraulic brake components. l Common hydraulic problems are: »Fluid leaks »Worn-out piston seals »Air in the system »Corrosion buildup Page 63

19. HYDRAULIC Pg 58 C

20. SLAVE CYLINDER Pg 59 C

21. ADJUSTABLE SLAVE CYL. Pg 59 C

22. CLUTCH DISC l Clutch disc transfers power from the flywheel to the transmission input shaft. l Disc must remain free of oil. l Clean hands. l Most clutch discs contain Asbestos. l If clutch disc is removed, replace if more than 50,000 miles. Page 74

23. FLYWHEEL l Scored flywheels can be resurfaced. l Check flywheel runout. l Check crankshaft endplay. l Clean oil and abrasives from flywheel. l Check ring gear teeth. l Mark flywheel and crankshaft for reassemble. Page 76

24. REMOVING THE CLUTCH l Caution l Mark driveshaft before removal. l Caution Asbestos l Warning check bolt length. l Match new parts with old parts Page 79 - 82

25. PILOT BUSHINGS l Three Types »Bushings »Ball Bearings »Torrington Needle Bearings l Use a tap to remove Bushings. l Use a puller to remove bearings. Page 82

26. RELEASE BEARING l Three Types »Non Constant Running Release Bearing –Adjustable Mechanical Linkage –Adjustable Hydraulic –Adjustable Cable »Constant Running Release Bearing –Self Adjusting Cable –Non Adjustable Hydraulic System »Internal Hydraulic Release Bearing (Pg 86) Page 84