• An automobile clutch normally provides dependable service

for thousands of miles

• However, service life can vary greatly depending on traffic
conditions and driver technique
• Every time the clutch is engaged, it is subjected to friction,
heat, and wear
 Verify the Clutch Problem

• Verify the complaint

• Test drive the vehicle
• Check the action of the clutch pedal
• Listen for unusual noises
• Feel for clutch pedal vibrations
 Common Symptoms
• Damaged or worn clutch parts can cause a variety of
symptoms:
• slipping
• grabbing
• dragging
• abnormal noises
• vibration
Common Clutch Problems
 Worn Clutch Disc

Causes clutch slippage and may damage flywheel and pressure

plate
 Separated Lining

This clutch disc exploded from

high speed shifts
 Burned Clutch Disc

Caused by oil contamination, not enough clearance, or the

driver riding the clutch
 Scored Lining

Caused by the use of an unmachined flywheel or badly scored

pressure plate
 Damaged Hub Splines

Damaged when the transmission was drawn into place with

bolts
 Disc Hub Wear

The hub rubbed on the flywheel because the clutch disc was
installed backward
 Dry Release Bearing

Produced a loud grinding noise anytime the clutch pedal was

pressed
Damaged Bearing Retainer Hub

Caused by a locked, spinning

release bearing
 Scored Pressure Plate

Caused by a worn clutch disc, the driver slipping the the clutch,
or binding linkage
Heat-Checked Pressure Plate

Caused by extreme slippage

 Broken Diaphragm Springs

Caused by installation
error, or adjustment too
tight
 Broken Release Levers

Caused by no free play, a bad release bearing, or improper part

alignment
 Free Travel (Free Play)

• Distance the clutch pedal or fork moves before the release

bearing acts on the pressure plate
• Some free travel is needed to ensure complete clutch
engagement
Free Travel (Free Play)
 Free Travel (Free Play)
• Excess free travel
• due to part wear that reduces clutch release action
• can cause clutch drag even with the pedal fully depressed
• Insufficient free travel
• due to bent parts or similar problems
• can cause clutch slippage
 Clutch Slippage
• Indicated when the engine races without a corresponding
increase in road speed
• Caused by the clutch disc sliding between the flywheel and
the pressure plate
• Occurs when accelerating, shifting, or climbing a hill
 Testing for Slippage
• Place the transmission in high gear
• Try to drive the vehicle forward by slowly releasing the clutch
pedal
• A good clutch should lock up, stalling the engine immediately
• A slipping clutch may allow the engine to run, even with the
clutch pedal fully released
 Causes of Slippage
• Some common causes:
• misadjusted clutch
• binding clutch linkage or cable
• worn clutch disc
• broken motor mount
• oil or grease on the clutch disc from a leaking oil seal
 Grabbing Clutch
• Produces a very severe vibration or jerking motion when the
vehicle is accelerated from a standstill
• Common causes:
• problems with the clutch disc
• problems with the flywheel
• problems with the pressure plate
• broken engine mounts
 Dragging Clutch
• Makes the transmission grind when trying to engage and shift
gears
• The clutch disc is staying engaged to the flywheel, turning the
transmission
• Common causes:
• too much free play
• warped or bent clutch disc
• oil, grease, or corrosion on the friction surfaces
• rusted or damaged input shaft splines
Abnormal Clutch Noises
• Squeaks whenever the clutch pedal is moved up or down
• worn or dry clutch release mechanism
• Noises when the clutch is initially engaged
• clutch disc problems such as metal-on-metal contact due to wear
 Abnormal Clutch Noises
• Noises when the clutch is disengaged
• dry or worn release bearing
• worn pilot bearing
• Noises when in neutral, disappearing when the clutch pedal is
depressed
• problems inside the transmission
 Pulsating Clutch Pedal

• Caused by runout of one of the rotating

components of the clutch assembly:
• flywheel warpage
• clutch housing improperly aligned with the engine
• pressure plate release levers bent or maladjusted
 Stiff Clutch Pedal
• Clutch release mechanism components may be worn or dry,
resisting movement
• Results from a problem with one of the parts involved in
clutch release:
• linkage
• cable
• hydraulic components
• clutch fork
• release bearing
• pressure plate
• After prolonged service or abuse, the clutch parts wear and
fail in service
• Occasional adjustment is required
• Repairs may be needed
 Clutch Linkage Adjustment

• Linkage is usually adjusted at the push rod attached to the

clutch fork
• The effective length of the rod can be increased to decrease
free play, or shortened to increase free play
Clutch Linkage
 Clutch Cable Adjustment
• Typically, the clutch cable housing will have an adjusting nut
• To increase clutch pedal free play, turn the nut to shorten the
housing
• To decrease free play, lengthen the clutch cable housing
• Some have an automatic adjusting mechanism
Clutch Cable Adjustment
 Hydraulic Clutch Adjustment

• Most hydraulic mechanisms do not require

adjustment
• If adjustment is necessary, adjust the length of the
clutch push rod on the slave cylinder
• Generally, lengthening the push rod decreases pedal
free play, shortening the rod increases free play
 Clutch Slave Cylinder

To rebuild a unit, hone the cylinder and

replace the cup and boot
 Removing the Clutch
• Always start by disconnecting the battery ground to prevent
accidental cranking
• Transmission or transaxle removal is usually needed
• On some front wheel drive vehicles, the engine must be
removed
• Always support the weight of the engine when removing the
transmission
 Transmission Jack

Use a transmission jack when lifting a heavy unit from the

vehicle
Removing the Clutch

Inspect each part as it is

removed
 Removing the Clutch
• Unbolt the bell housing
• Mark the pressure plate and flywheel to ensure correct
balancing when reassembling
• Slide a pilot shaft into the clutch disc
• Loosen the pressure plate bolts a little at a time to spread out
the stress
• Be prepared to support the heavy clutch parts when
removing the last bolt
 Removing the Clutch

A pilot shaft will keep the clutch disc from falling as the
pressure plate is removed
Inspecting a Clutch
 Pilot Bearing Service

Check the pilot bearing for wear

If worn, remove it and install a new one
 Flywheel Service
• Closely inspect the surface for cracks, scoring, or
discolored areas caused by overheating
• Measure runout with a dial indicator
• If the flywheel is warped, or the surface is scored,
it may be resurfaced or replaced
 Clutch Disc Service

Inspect the depth of the rivet holes

The friction disc is normally replaced
 Release Bearing Service
• To check, turn the bearing while pushing on it
• The bearing should rotate smoothly
• Inspect any spring clips used to hold the bearing on the end
of the fork
• To replace a bearing, drive it off its collar
• Press a new bearing into place on the collar
 Installing a New Bearing

Use a small amount of grease to help it slide on the

transmission hub
 Hydraulic Release Mechanism
Service
• Problems may be caused by fluid leaks
• The rubber cups inside the cylinders can wear and begin to
leak
• If enough fluid is lost, the reservoir may empty and the
clutch may fail to disengage
 Clutch Master
Cylinder

Rebuild or replace leaking parts

 Bleeding the System
• Bleeding of air will be required any time the system is
disassembled
• A bleeder screw is often found on the slave cylinder
• Pressurize the system with a pressure bleeder or by pumping
the clutch pedal
• Open the bleeder screw to vent air bubbles
• Repeat until the bubbles are gone and the fluid is clear
 Installing the Clutch
• Use a pilot shaft to center the disc
• Start the pressure plate bolts by hand
• Never let grease contact the friction surfaces
• Tighten each pressure plate bolt a little at a time in a
crisscross pattern
• Slide the pilot shaft out of the clutch
Installing the Clutch
 Installing the Clutch
• Install the clutch fork and release bearing in the bell housing
• Install the bell housing on the engine
• Install the transmission or transaxle
• Reconnect the drive shafts, linkages, cables, wires, and battery
cable
• Adjust the pedal free play to specs
• Road test the vehicle