Trouble Shooting

PROBLEM
Chatter / Judder
  1. Loose broken or worn engine mounts
  2. Pedal linkage worn
  3. Loose or cracked clutch housing.
  4. Spring shackles & mountings loose /worn
  5. Misalignment
  6. Oil or grease on facings
  7. Warped or bent driven disc assembly
  8. Warped or bent driven disc assembly
  9. Worn pilot bearing.
  10. Wrong spring pressure in cover assembly
  11. Release levers not parallel.
  12. Glazed facing/Pressure plate.
  13. Clutch disc bent with pressure plate contact on contact on inner diameter of clutch facing during engagement
Hard Pedal
  1. Worn pedal linkage
  2. Worn cross shaft , bushing or yoke
  3. Binding in pedal linkage (Rod or Cable)
  4. Excessive spring pressure in cover assembly
  5. Contact pad of release bearing assembly worn by release yoke
  6. Defective pilot bearing/bush disc assembly and spline shaft.
  7. Gear box not aligned properly.
Aggressive / Jerky Engament
  1. Worn or loose pedal linkage.
  2. Excessive backlash in power train
  3. Warped driven disc
  4. Worn hub splines.
  5. Worn spline on input shaft.
  6. Improper facing material.
  7. Loose cerametallic button facing.
  8. Burned cerametallic button facing.
Gear Shifting Hard
  1. Broken or loose engine mounts.
  2. Worn or loose pedal linkage.
  3. Excessive idle speed.
  4. Loose or worn out facing.
  5. Improper facing material.
  6. Warped or bent driven disc.
  7. Worn hub splines.
  8. Worn or rusty splines on input shaft.
  9. Worn pilot bearing.
  10. Worn or misaligned drive pins.
  11. Insufficient release bearing travel.
  12. Misalignment of gear box.
  13. Stuck /jammed clutch disc.
Slippage
  1. Oil or grease on facing.
  2. Loose or worn facings.
  3. Flywheel burned , cracked or dished.
  4. Insufficient pressure on pressure plate.
  5. Binding in pedal linkage.
  6. Improper facing material.
  7. Incorrect flywheel depth.
  8. Incorrect disc thickness.
  9. Inadequate free play of clutch plate.
  10. Worn / damaged pressure plate assembly.
Vibration
  1. One or more units in power strain out of balance.
  2. Worn out spline shaft.
  3. Worn crankshaft bearings.
  4. Worn drive pins or slots.
  5. Worn or loose engine mounts.
  6. Loose or out of balance universal joints.
  7. Clutch out of balance.
  8. Worn disc splines.
  9. Clutch facing damaged.
SOLUTION
  1. Tighten or replace
  2. Replace linkage.
  3. Tighten or replace.
  4. Tighten or replace.
  5. Re-align.
  6. Install new disc assembly & correct oil leak.
  7. Install new disc assembly.
  8. Replace.
  9. Replace.
  10. Replace with proper cover assembly.
  11. Recheck installation.
  12. Replace new disc assembly & pressure plate.
  13. Replace new disc assembly.
  1. Replace with new linkage.
  2. Replace with new cross shaft bushing or yoke.
  3. Lubricate, adjust or replace.
  4. Install proper cover assembly.
  5. Replace release bearing assembly and release yoke also check for proper alignment to provide best linkage operating positions.
  6. Replace pilot bearing/bush disc assembly and spline shaft.
  7. Realign gear box.
  1. Replace or tighten.
  2. Adjust or replace worn parts.
  3. Install new disc assembly.
  4. Install new disc assembly.
  5. Replace shaft.
  6. Install proper disc assembly.
  7. Install new disc assembly.
  8. Install new disc assembly.
  1. Replace or tighten.
  2. Replace or tighten.
  3. Adjust to manufacturers specification.
  4. Install new disc assembly.
  5. Install proper disc assembly.
  6. Install new disc assembly.
  7. Replace with new disc assembly.
  8. Clean or replace.
  9. Replace.
  10. Replace or re-align.
  11. Repair or replace linkage.
  12. Re-align properly.
  13. Grease the spline of hub & shaft.
  1. Install new disc assembly & correct oil leak.
  2. Install new disc assembly.
  3. Replace or re-grind to manufacturers specification.
  4. Install new cover assembly.
  5. Lubricate and adjust.
  6. Use correct facing or replace disc assembly.
  7. Grind flywheel to manufacturers specification or replace.
  8. Install new disc assembly.
  9. Adjust free play.
  10. Replace new disc assembly.
  1. Replace faulty components.
  2. Replace.
  3. Replace.
  4. Replace drive pin ,flywheel & or intermediate plate.
  5. Replace or tighten.
  6. Tighten or replace , check for balance.
  7. Install balanced unit.
  8. Replace disc assembly.
  9. Replace new disc assembly.

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