Clutch trouble shooting

I. Difficulty Changing Gears

Cause	Action Needed
The transmission was forced into position damaging the splines of the disc hub.	Install new clutch and carefully control the position and alignment of the transmission during installation.  Use a transmission jack and possibly install temporary guide pins to assist in aligning the transmission to the engine.
The cover assembly has been dropped.	Install new clutch.  Always inspect the drive straps for damage before installation.
The cover has not been located on the flywheel dowel pins correctly.	Install new clutch and ensure all flywheel dowel pins are in position and in good condition.  Do not use air tools to tighten the bolts.
The self-adjusting mechanism fails to lock due to worn ratchet and pawl.	Repair self-adjusting release system.  Replace ratchet and pawl.
Release bearing travel is insufficient.	Inspect release mechanism for full travel or lost motion due to worn parts.  A stamped steel release arm can wear and break.  Always remove and check arm and external pivots.  Install new fork bushings and lubricate as required with high melting point grease.

II. Loss of Drive

Cause	Action Needed
Transmission has been hung on the shaft during installation.  Angular misalignment of the transmission to engine.	Install new clutch and support transmission during installation.  Do not allow the transmission to hang on the clutch disc during installation.  Check for missing bell housing dowel sleeves, worn pilot bushing/bearing or foreign matter between transmission and engine including wires, cables or brackets.  The above problems will cause cracking in the segments, leading to separation of the damper and facing segments.
Driver resting foot on the clutch pedal resulting in release system sticking.	Install new clutch.  Check all components of the release system, particularly self-adjusting release systems, and guide tubes.  Check for leaking oil seals.
The clutch has been disengaged at speeds in excess of the maximum for the gear selected or the incorrect gear has been selected.  This has caused the facings to burst.	Install new clutch and educate the driver.

III. Noise & Vibration

Specific Circumstance	Cause	Action Needed
Noisy Clutch	Broken location lug due to worn release fork and or no lubrication	Replace any worn components and install new clutch.  Apply a liberal amount of high temp grease to the fork contact pads.
Chattering After Changing the Clutch	Flywheel surface worn	Replace or resurface flywheel and install new clutch.
Grating Noise when Pulling Away	No lubrication on the clutch fork contact areas	Clean and lubricate using the grease supplied with the Valeo Clutch Kit.
Noise when in Neutral	Oil or grease has contaminated the disc pre-damper making it ineffective	Install new clutch and sparingly use the spline grease supplied in the Valeo Clutch Kit.
Noise During Release	Worn pilot bearing or bushing	Replace pilot bearing or bushing
Noise	Installation is missing the transmission to engine dowel sleeves or pilot bushing/bearing.  This has created a concentric misalignment of the engine to the transmission.  The torsion damper is destroyed, damper springs are broken, stop pins show contact from the hub flange and the hub pilot is worn.	Carefully inspect for missing dowel sleeves and worn dowel sleeve holes in the bell housing.  Replace pilot bushing/bearing and inspect the transmission to engine alignment.
Clatter on Engagement	Excessive amount or incorrect type of grease applied to input shaft	Install new clutch and use the spline grease supplied in the Valeo Clutch Kit.

IV. Clutch Slippage

Specific Circumstance	Cause	Action Needed
Slipping and Impossible to Change Gear	Overheating due to excessive clutch slippage	Install new clutch kit.  Check all components of the release system, particularly self-adjusting release systems and guide tubes.  Check for leaking oil seals.
Slipping and Chattering	Driver resting foot on the clutch pedal or incorrect clutch adjustment	Do not use the clutch pedal as a footrest.  Inspect for correct clutch adjustment.
Slipping	The self-adjusting mechanism has become jammed	Replace or repair the self-adjusting mechanism or in the case of semiautomatic adjusters - reset.
Slipping	Clutch facing material is oil contaminated	Replace leaking oil seals.  Clean off excess oil and install new clutch.

V. Clutch Pedal