Clutch Faults Check List
1. Incorrect adjustment/setting of release mechanism.
2. Clutch worn out (usually Drive Plate facing worn thin).
3. Oil contamination, gearbox or crankshaft oil seals are defective.
4. Faulty Cover Assembly, e.g. broken or weak diaphragm spring.
5. Excessive amount or incorrect type of spline grease applied to the spline shaft when fitting the clutch (lithium grease not copper type grease should be used).
6. Incorrect Cover Assembly fitted, i.e. underrated for application.
7. Poor driving technique, i.e. resting foot on clutch pedal.
8. Clutch abuse causing facing materials to overheat impairing their frictional value.
9. Loss of clamp force due to wear in the flywheel face.
10. Auto adjusting mechanism failing to give free play.
11. Hydraulic mechanisms failing to give free play (master cylinder or slave cylinder at end of travel or in wrong position to allow passage of fluid back to reservoir this changes as clutch wears).
Non Clearance (Difficulty in engaging gears, clutch fails to release).
1. Release mechanism not set correctly.
2. Clutch pedal travel impeded.
3. Wear in release mechanism or air in hydraulic type system.
4. Drive plate distorted, (damaged in transit or during fitting by bending it with primary shaft).
5. Fault in cover assembly. E.g. loose or broken fulcrum ring, weak/bent drive straps (this can easily happen by dropping cover just a few inches).
6. Spigot bearing/bush seized (where applicable).
7. Drive plate / primary shaft spline damage or dirty not allowing plate to move freely.
8. Release bearing/fork retention clips faulty.
9. Oil contamination prevents driven plate releasing from the flywheel or cover assembly pressure plate.
10. Excessively worn or stretched release cable, such that the auto adjust mechanism is not capable of achieving the correct setting.
11. Faulty or worn auto adjust mechanism (pressing the pedal gives the illusion that the clutch is being operated).
12. Debris from old clutch jamming behind Diaphragm of cover
13. Spring popped out of plate and jamming clutch cover.
14. Clutch plate material too thick.
15. Wrong parts fitted.
1. Operation of cover assembly faulty.
2. Action of the release bearing is incorrect.
3. Worn clutch components.
4. Worn vehicle components, i.e. engine or transmission mountings, transmission couplings, suspension components.
5. Sticking or worn release mechanism.
6. Cover assembly pressing distorted during fitting.
7. Corrosion, damage or wear of drive plate spline or gearbox spline shaft.
8. Grooved, worn, distorted, heat crazed, or hot spotted fly wheel.
9. Oil contamination.
10. Bad working practice i.e. not cleaning bell housing, flywheel, touching plate lining or mating surfaces with oily fingers (resulting in contamination of plate lining).
The above is not an exhaustive list of clutch faults, others may be encountered which are peculiar to particular vehicle types.