CLUTCHVIAWEB: Clutch makes a noise

The following easy to use charts are provided to enable clutch problems to be easily identified and make diagnosis simpler.

Problem	Cause	Remedy
Bearing running eccentrically to diaphragm fingers	Bearing not centreing	Renew bearing
No drive		Renew pressure plate or driven plate
Incorrect driven plate	Torsion damper incorrect for vehicles application	Fit correct driven plate
Torsion damper broken	Incorrect damper	Fit correct driven plate
Release bearing defective	Not rotating smoothly	Renew bearing
Spigot (pilot) bearing defective	Bearing seized	Renew bearing
Damaged damper spring breakout	Incorrect driving habits Wrong gear selection	Renew driven plate

1. Worn diaphragm spring fingers

Cause

• Release bearing seized

• Faulty release system

• Incorrectly adjusted release system

2. Damaged idle damper

Cause

• Incorrect fitting

• Incorrect driven plate

3. Retainer spring damaged

Cause

• Incorrect fitting

-> Incorrect diaphragm spring in clutch assembly

4. Spring window damaged
Cause
• Incorrect driven practice
-> Driving the vehicle in too high a gear at low revs
• Incorrect clutch driven plate

5. Torsion damper spring broken out
Cause
• Facings contaminated with oil
• Out of tune engine
• Faulty release mechanism
-> Chatter vibration damages the torsion damper

6. Torsion damper stop rivet worn
Cause
• Incorrect driven practice
-> Driving the vehicle in too high a gear at low revs
• Incorrect clutch driven plate

7. Spline damaged on one side forming a taper, torsion damper damaged
Cause
• Faulty spigot (pilot)
• Misalignment condition between engine and gearbox

8. Worn splines
Cause
• Worn or missing spigot (pilot) bearing
• Misalignment condition between engine and gearbox
• Damaged gearbox input shaft
• Induced torsional vibration

9. Casing and ball bearing damage
Cause
• Overheating of release bearing due to incorrect clearance causing loss of grease and break up of bearing

10. Release bearing worn
Cause
• Incorrect adjustment of release arm
• Insufficient bearing preload
(specification 80 – 100 N)

11. Gearbox snout worn
Cause
• Incorrect grade of grease or no grease used
• Damaged release bearing

12. Running surface on release bearing worn
Cause
• Release system worn
• Incorrect bearing preload
(specification 80 – 100 N)

13. Worn release lever
Cause
• None or incorrect grease used

14. Release bearing tappet points worn
Cause
• Tappet points not lubricated
• Release system worn

15. Push rod wear mark off centre
Cause
• Damaged release system
-> Bearing worn
-> Guide bush worn

16. Damaged bearing lugs
Cause
• Damaged release system

17. Bearing fouling clutch cover
Cause
• Clutch cover and release bearing mismatch

18. Torsion damper broken
Cause
• Incorrect driven practice
-> Driving the vehicle in too high a gear at low revs
-> Grease/oil contaminated facing