Modes of Clutch Failure

Failure Diagnosis
LuKs guide to troubleshooting clutch-system

failures and malfunctions
agricultural vehicles
General tips on installing
commercial vehicle clutches 2835
Diagnostic charts 3639
C Clutch judder 1922
B Clutch slip 1518
LuK tips on avoiding clutch system
failures and malfunctions 4 5
A Clutch fails to disengage 614
D Clutch makes a noise 2326
Contents
3
This manual is for the use of all of our employees,
business associates, and friends who sell, install,
or report on LuK-clutches. It is primarily intended
to be a source of information that will simplify
diagnosing the causes of failures and malfunc-
tions of commercial vehicle clutch systems. Its
content is confined to typical clutch-system
defects and is not designed to be a comprehen-
sive list.
2008
LuK-Aftermarket Service oHG,
D-63225 Langen, Germany
Technical Service Dept.
Reproduction, copying, or translation hereof
in whole or in part requires our prior written
permission and crediting the source
August 2008, 3
rd
edition
4
LuK tips on avoiding clutch system failures and malfunctions
Flywheel
The running surface of the flywheel, which mates to the driven plate,
may show signs of wear after extensive mileage. Scoring, glazing,
and/or gouges indicate that the flywheel has been overheated, and
these must be removed, however they should never be refaced beyond
the tolerances laid down by the manufacturer. It is important however,
that the same amount is taken from the bolting surface. Also take this
opportunity to check the starter ring gear.
Spigot (Pilot) bearing
They may be no larger than a thimble, but they can cause serious
problems. If they bind, the clutch may fail to disengage. They can
also cause noise and angular misalignment, and thus damage to the
driven plate. A missing spigot (pilot) bearing may cause the transmis-
sion input shaft to wobble and destroy the torsional-vibration damper
and the input shaft bearing.
Oil seals
Leaking oil seals can severely damage the clutch. Even slight traces
of grease or oil can adversely affect clutch operation. Traces of oil in
the bell housing or on the clutch driven plate indicate that seals will
need to be replaced. Seals on older vehicles with high mileage should
always be replaced as a precaution. The major cause of clutch failures
and malfunctions is still leaking oil seals.
Driven plate
Although each and every driven plate is checked for correct operation
before it leaves the LuK factory, it cannot be ruled out that they might
suffer a damage on their way to the garage.
Every driven plate should be checked for lateral runout (the maximum
tolerance is 0.5 mm) prior to installation. Excessive lateral runout is
not covered under warranty.
Release bearing
Release bearings cannot be checked for correct operation at garage
level. They should always be replaced whenever the clutch is replaced.
The bearing should slide freely on their guide tube without tilting.
A worn running surface will invariably cause noisy operation.
Release-bearing guide tubes
Check the guide tube for correct fitment. Guide tubes should be
centered and parallel to the transmission input shafts. Damaged or
worn areas on guide tubes may prevent the release bearing from
sliding freely. This can lead to judder, clutch slip, heavy or difficult
clutch operation. Damaged or worn guide tubes should always be
replaced as part of a professional clutch replacement.
Release fork
Check the release fork for ease of operation. Excessive play in release-
shaft bushes reduces release bearing travel. Uneven wear on the
contact points will cause the release bearing to tilt and prevent the
release bearing from sliding smoothly on its guide tube. Worn, bent,
or broken release forks may prevent the clutch from disengaging.
Release shaft
The release shaft will have to be removed before it can be inspected
for wear or damage, since the bearing surfaces and bearings cannot
be inspected while in place. Damaged or worn shaft bearings will
cause the shaft to tilt, which will create binding and/or a juddering
clutch. Re-lubricate the bearings before replacing the shaft. The
LuK-AS part number for the correct high-melting-point grease is
414 0014 10.
Clutch cable
Clutch cables cannot be accurately checked for proper operation at
garage level. Since clutch cables are subject to wear, they should be
replaced whenever clutches are replaced.
Make certain that clutch cables are correctly routed when installing
them. They should never be routed around sharp corners or kinked.
LuK-ASs line of clutch cables is covered in the associated sales
literature (only LHD).
Centrally actuated release mechanism
Like the clutch, the centrally actuated release mechanism is subject
to wear, which may not always be visible during normal operation.
If only the clutch is replaced, it might be that the centrally actuated
release mechanism could fail soon after clutch replacement, necessi-
tating a second, unnecessary visit to the garage, since the worn
centrally actuated release mechanism was not identified the first
time around. Professional clutch replacement should always involve
replacing the clutch pressure plate, driven plate, and centrally
actuated release mechanism.
Please take care to use the correct fluid for refills. In some cases you
must use brake fluid (black seal) , in others mineral oil (grey seal).
Alignment
Correct alignment of the clutch is frequently ignored. If clutches
have not been correctly aligned, they will start juddering or fail to
disengage immediately afterwards. The clutch should thus always
be checked for correct alignment on the flywheel.
Lubricants
Grease that contains no suspended particulates should be used
for lubricating splines and release bearings/guide tubes. LuK-AS
has the correct high-melting-point grease for clutch replacements
available under Part No. 414 0014 10. Once grease has been applied
to the splines on the gearbox input shaft, slide the driven plates
hub onto the shaft and remove any excess grease.
Chemically nickel-plated hubs should not be lubricated.
The Service life of clutch facings
Since friction clutches are dry clutches, and wear during the slipping
phase, i.e., while the rotational speed of the driven plate is being bro-
ught up to that of the flywheel, is normal. The basic pre-requisite for a
long clutch life is ensure that the clutch release mechanism is in per-
fect working order and that the clutch is not abused while driving.
Clutch life may be adversely affected by the following:
revving up the engine when starting off or starting off in the
wrong gear,
stop-and-go driving in heavy traffic,
manouvering in close confines,
slipping the clutch for extended periods,
preventing the vehicle from rolling back on inclines by slipping the
clutch, and failing to use the accelerator pedal to match speeds
when downshifting.
Hotline number for problem cases:
+49 (0) 1801-753-333 or in the U.K.
+44 (0) 8457 001100
Major causes of problems:
LuK tips on avoiding clutch system failures and malfunctions
5
Certain criteria should be kept in mind and certain procedures obser-
ved when assessing the malfunction of clutch systems. Diagnosing
failures or problems in order that they may be efficiently and perma-
nently eliminated. The following should be observed.
1. Determine the reason(s) for the complaint
2. Troubleshooting
3. Diagnose the failure or problem
4. Eliminate the cause of the failure or problem
The reason(s) for the complaint provide basic information in the sub-
sequent troubleshooting, which may identify one or more causes for
complaint. The clutch should be visually inspected and subjected to
dimensional checks if necessary, either while it is still installed or after
it has been removed. This will provide an indication that will help in
the correct diagnosis and will lead to the repair or replacement of the
affected parts.
Determining the reason(s) for the complaint
Accurate information regarding the complaint is indispensable if the
causes are to be eliminated. Since the reasons may be counted on
the fingers of one hand and it can be readily and clearly described.
The five possible reasons for complaints
about clutches:
Troubleshooting
Troubleshooting confined to a specific area can start once a clear-cut
statement of the reason(s) for the complaint has been identified.
However, the error of immediately starting to remove the clutch,
which, in most cases, represents the bulk of the work to be carried
out, is frequently undertaken. Where as searching for the cause of the
failure/ or fault in areas where it might be eliminated using relatively
simple means, namely, in areas of the clutch system other than the
clutch itself is frequently neglected.
The cause of clutch failures or faults is not always attributable to a
clutch malfunctioning. A closer look would show that there are a
variety of external influences that can affect clutch operation.
Clutch pedal is heavy in operation
Clutch makes a noise
Clutch judder
Clutch slip
Clutch fails to disengage
Here are a few examples:
Incorrectly adjusted carburettors or fuel-injection systems may cause
rough idling that will be reflected in a juddering clutch while driving.
An incorrectly adjusted ignition system may also cause phenomena,
such as a judder when the clutch is engaged. In addition, running
on after the engine is switched off transmits sudden jolts to the
tangential leaf springs. Bent tangential leaf springs will cause disen-
gagement problems.
Damaged or weak engine mountings will cause the engine to move
from its position and then bounce back when the clutch is engaged,
which causes a transition between static and dynamic coefficients of
friction at the contact surface of clutch facings and results in judder.
Heavy accelerator pedal actuation also causes juddering. A combi-
nation of a binding accelerator linkage and very weak engine mounts
causes the drive train to rock.
A worn-out clutch cable causes disengagement problems or juddering.
Failure to correctly adjust clutch cables will cause anything from
slipping and disengagement problems to the total destruction of
clutch components.
A malfunctioning hydraulic clutch-actuation system will cause disenga-
gement problems or judder.
Distorted transmission mountings or missing spigot (pilot) bearings
cause angular misalignment between the crankshaft and transmission
input shaft which results in judder or disengagement problems. The
subsequent Wobbling motion of the driven plate during engagement
and disengagement because this angular misalignment causes fractu-
res around the rivets that hold the segments in place.
Worn splines on the transmission input shaft will cause erratic
movement during load changes, which can bend tangential leaf
springs and cause disengagement problems or juddering.
More technical information:
www.RepXpert.com or www.Schaeffler-Aftermarket.com!
Failure diagnosis/causes of failures
Right Wrong!
6
1. Linings torn off
2. Linings torn off
3. Pressure plate lugs broken
Cause
The rotational speed of the driven plate has
exceeded the burst speed of the lining mate-
rial, this condition occurs when the vehicle
is allowed to coast with the clutch pedal
depressed and the vehicle speed exceeds
the maximum speed of the gear selected.
This sort of damage is independent of engine
rpm. The determining factor is transmission
input-shaft rpm.
Cause
Lack of release bearing clearance
Engine vibration damper defective
Fuel injection system incorrectly adjusted
A
Cause
Worn flywheel face not machined flat
Cause
Engine vibration damper defective
Engine torsional vibrations have caused the
circlip securing the pivot pin to pop off
Fuel-injection system incorrectly adjusted
Cause
Incorrectly adjusted release bearing
Worn out torsion damper on the crankshaft
Incorrect setting of injectors
4. A release-lever pivot pin has
drifted out
5. Broken pivot pin
6. Pressure plate broken
7
Cause
Pressure-plate overheating due to slipping
the clutch for excessively long periods
Clutch was slipping due to worn friction
Binding in the release system
Defective slave cylinder
Oil on linings due to a leaking shaft seal
A
8
7. Centering ridge on flywheel
broken off
8. Tangential leaf spring broken
9. Tangential leaf spring bent
Cause
Clutch incorrectly installed
Clutch not aligned to the flywheel ridge
Bolts not torqued down evenly
Cause
Play in the drive train
Driver error
Poor gear-shifting habits
Cause
Play in the drive train
Driver error
Improper storage
Clutch fell or was dropped during installation
A
10. Broken clutch levers
11. Worn clutch levers
12. Worn spring fingers
9
Cause
Faulty release mechanism
Release bearing failure
Cause
Release bearing failure
Cause
Release bearing seized
A
10
13. Clutch cover pressing bent
14. Pivot ring removed
15. Hub splines damaged
Cause
Incorrect fitting
Mounting bolts not uniformally tightened
Dowels in flywheel not correctly aligned
Cause
Incorrect fitting
Pivot ring removed following fitting
Pivot ring is not an aid to fitment!
Cause
Incorrect fitting
Captive disc shaft incorrectly aligned
PTO hub shaft incorrectly aligned
Pressure plate not aligned to flywheel step
Pressure plate not torqued down correctly
Wrong drive plate installed
A
Cause
Spigot (pilot) bearing worn
Angular misalignment of engine and
transmission
Cause
Incorrect fitting
The clutch disc carrier was damaged by
the transmission/PTO input shaft due to
misalignment when the transmission was
reinstalled on the engine
16. Rust on the hub
17. splines chewed out on one side,
tapered wear on splines
18. Clutch disc distorted
11
Cause
Hub splines were not lubricated
A
Cause
Incorrect fitting
The clutch disc carrier was damaged by
the transmission/PTO input shaft due to
misalignment when the transmission was
reinstalled on the engine
Cause
Incorrect fitting
The transmission was allowed to drop down
during installation.
Engine-transmission angularly misaligned
Cause
Incorrect fitting
Driven plate fitted wrong way around
Incorrect driven plate
12
19. Clutch disc distorted
20. Segment cushion broken
21. Fouling marks on the hub
A
Cause
Vehicle has been left standing for a long time
Cause
Sintered friction material not bedded in
Tractor was put under heavy load
immediately following fitting.
Excessive slip due to fitment of clutch
disc against worn and grooved flywheel
Cause
Worn release fork
Worn guide tube
Worn release shaft bearings
Release-fork-bearing surface worn
22. Facing stiction
23. Sintered friction material
destroyed
24. Release-fork-bearing surface
worn
13
A
14
25. Release bearing claering
26. Casing and bearing damaged
27. Gearbox snout worn
Cause
Insufficient bearing preload
(specification 80100 N)
Incorrect adjustment of the release fork
Cause
Overheating of the release bearing due to
incorrect clearance causing loss of grease
and break up of the bearing
Cause
Offset wear by the release fork
A
Cause
Overheating
Lining worn beyond permissible limits
Cause
Incorrect preload
Cause
Oil on linings
Leaking shaft seal(s)
Lining coefficient of friction decreased
due to allowing the clutch to slip for too
long (overheated linings)
Clutch slip
1. Severe scoring and glazing on
the pressure plate
2. Diaphragm-spring fingers worn
3. Lining surfaces glazed
15
B
16
Clutch slip
4. Grease/oil on linings
5. Linings worn down to the rivet
heads
6. Friction material worn to rivet
head
Cause
Too much grease used on hub
Excess grease on the hub splines was not
removed and grease ran
Leaking engine or transmission shaft seal
out onto the linings
Cause
Excessive lining wear
Vehicle was still being driven, even though
the clutch was slipping.
Incorrect driven practice
Allowing the clutch to slip for too long
Improper use of the clutch
Defective release system
Cause
Excessive friction material wear. Vehicle was
still being driven, even though the clutch was
slipping
Clutch slipped for long periods?
B
Cause
Worn flywheel was not replaced.
Worn flywheel mating surface was not
turned down
Cause
Clutch disc installed backwards
Incorrect clutch disc installed
Flywheel modifications not made
Cause
Release-shaft bearings not lubricated
Release shaft and/or its bearings worn
Clutch slip
7. Lining on flywheel side scored
8. Incorrect fitment
9. Release shaft binding
17
B
18
Clutch slip
10. Worn clutch levers
Cause
B
Cause
Oil or grease on the facing
Stiff clutch linkage
Worn engine mountings
Worn transmission linkages
Engine badly tuned
Cause
Excessive clearance in the drive train
Improper storage
Clutch fell or was dropped during installation
Cause
Release fork worn
Release-bearing mountings worn
Release shaft mounting worn out
Clutch judder
1. Heavy chatter marks on the
pressure plate
2. Tangential leaf spring bent
3. Release-fork bearing surface worn
19
C
20
Clutch judder
4. Grease/oil on linings
5. Lining on flywheel side scored
6. Spline size damaged
Cause
Too much grease used on hub splines
Excess grease was not removed during
installation and grease ran out onto the
linings
Cause
Worn flywheel was not replaced
Worn flywheel mating surface was not turned
down
Cause
Incorrect fitting
The transmission input shaft has been forced
into the driven plate splines (the driven plate
was not aligned when the pressure plate was
installed).
Incorrect driven plate fitted
C
Cause
Worn release fork mountings
Worn guide sleeve
Cause
Worn input shaft was not replaced
Cause
Worn release shaft and/or bearings
Clutch judder
7. Release fork worn
8. Transmission input shaft
worn out
9. Release shaft binding
21
C
22
Clutch judder
10. Flywheel glazed and scored
11. Faulty clutch mechanism
Cause
Flywheel not refaced/replaced
Cause
Worn cable
Inner cable worn and unable to move freely
Old cables whilst they may look sound are
worn
C
1. Diaphragm-spring fingers worn
2. Signs of wear on torsional
vibration damper
3. Fouling marks on the hub
23
Cause
Insufficient preload
Release bearing seized
Cause
Clutch disc installed backwards
Incorrect clutch disc installed
Flywheel modifications not made
Cause
Incorrect fitting
Driven plate fitted wrong way around
D
Cause
Driving too long at excessively low engine
speeds has caused the damper's efficiency
limits to be exceeded.
Wrong driven plate installed
Cause
Oil on clutch linings
Improperly tuned engine
Wrong driven plate installed
Juddering damages the torsonal-vibration
damper.
Cause
Worn spigot (pilot) bearing
Angular misalignment of engine and
transmission
24
4. Torsion damper retainer plate
broken
5. A torsion spring has broken out
6. Hub spline chewed out on one
side, tapered wear on hub
splines, torsional-vibration
damper destroyed
D
Cause
Badly tuned engine
Faulty or incorrectly set injectors
Induced torsional vibration in tractor PTO
Cause
Cause
Insufficient bearing preload
(Specification 80100 N)
7. Worn splines
8. Casing and bearing damaged
9. Release bearing worn
25
D
26
10. Gear box snout worn
11. Release-fork bearing surface
worn
12. Release fork worn
Cause
Offset wear by the release fork
Cause
Worn release-shaft bearings
Worn guide tube
Cause
Worn guide tube
Worn release-shaft bearings
D
27
D
28
The LuK way to...
...cost-effective, efficient clutch replacements
/
Clutch pressure plate
:
Clutch driven plate
Release bearing
M
Flywheel
?
Transmission input
shaft
!
Crankshaft
Right Wrong!
First things first:
Are the correct parts available?
It is crucial to check before installation, compare
with dismantled parts.
In particular, the following should be noted:
Check wear of the pilot bearing; renew if necessary.
Check shaft sealing rings on engine and transmission
side for leakages and replace if necessary.
Flywheel: Check friction surface for scoring and
cracks. Note the prescribed tolerances for reworking!
Caution! Rework the screw fixing surface for the
clutch to the same extent as the treated friction
surface.
DMF: The friction surface may not be reworked!
Check the clutch disc for lateral runout prior to
assembly (max. 0.5 mm).
Check the clutch shaft for damage, lubricate spline
profile or shaft. Remove excess grease.
Manufacturer's recommendation:
LuK high-performance grease (LuK-AS item no.
414 0014 10). Grease containing suspended solids is
not suitable.
Note! Chemical nickel-plated splines are not to be
lubricated!
Note the correct installation position of the clutch
disc! Use centering pins for assembly.
Check the guiding sleeve of the release bearing
for wear and replace if necessary; use suitable
lubrication.
Tighten the clutch assembly crosswise with the
prescribed torque. Always remove and install the
SAC clutch with the special tool approved by LuK-AS
(LuK-AS item no. 400 0072 10).
Take into account the centering of the clutch assembly
on the flywheel! With external centering, take into
account the condition of the pilot diameter of the
clutch assembly and the flywheel.
Inconsistencies in diaphragm spring tabs or release
levers, caused by thick ness tolerances in the friction
lining, regulate themselves after a short run-in time.
If the fixed setting carried out by LuK in the factory
is readjusted, the warranty is void!
Check clutch operation for function and wear! Replace
the clutch cable - check the bearings.
Check clutch operation for function and wear! Replace
the clutch cable - check the bearings. Check the
hydraulic system for leaks and vent if necessary.
Check the release stroke of the slave cylinders piston
rod. Check whether the initial position is reached.
When changing the clutch, also replace the hydraulic
concentric slave cylinder (CSC).
Check the alignment of the engine to the gearbox.
Replace dislodged gearbox dowels!
Set release bearing clearance at 2-3 mm. Constant
running bearings are o perated with a pre-load of
80100 N. Only combine bearings which have plastic
sleeves with metal guiding sleeves.
1
2
3
4
5
6
8
9
10
11
12
7
13
14
The LuK Clutch Course
29
Drive side
T
o
r
s
i
o
n

m
o
m
e
n
t

[
N
m
]
Main damper
Overrun
Idle damper
Torsion angle []
Driven plates for heavy vehiclestheir design and operation
Lining rivet
Inner compression spring
on primary damper
Outer compression spring
on primary damper
Compression spring
on secondary idle damper
Splined hub
Segment rivet
Hub flange
Lining
Spring segment
Retainer plate
4
8
1
5
2
3
7
6
9
0
1
2
3
4
5
6
7
8
9
0
30
Tractor clutch with sequential P.T.O.
Cover housing
Main drive pressure plate
P.T.O. pressure plate
Diaphragm spring
Main drive clutch plate (with cera-metallic pads)
P.T.O. plate (with organic facing)
Main drive lever
P.T.O. lever
Flywheel
Connecting rod (pulling)
Connecting rod (pushing)
Adjusting screw
Lock nut
Adjusting nut
Location pin
Anti rattle spring
Pivot pin
Tangential strap
Rivet
Strap securing bolt
Balance hole
1
2
3
4
5
6
7
8
9
0
q
w
e
r
t
2
1
8
7
4
6

q
w
r
5
q
1
e
0
1
q
t
4
6
0
3
2
w
7
5
9
8
31
Tractor clutch with independent P.T.O.
Cover bracket
Diaphragm spring
Main drive plate
(with cera-metallic pads and torsion damped)
P.T.O. plate
(with organic facing and solid center)
Main drive lever
P.T.O. lever
Flywheel
Adjusting screw
Lock nut
Adjusting nut
Split wheel
Hairpin spring
Pivot pin
1
2
3
4
5
6
7
8
9
0
q
4
6
0
3
2
5
9
8
q
1
4
6
q
0
3
7
1
5
q
8
2
32
Fixed P.T.O. tractor clutch
Cover bracket
Pressure plate
Diaphragm spring
(with reinforced fingers and built-in cooling effect)
Main drive plate
(with cera-metallic pads and torsion damper)
Flywheel
Fixed P.T.O. (with torsion damper)
Rivet
Fulcrum ring
Tangential strap
Release bearing
Balance hole
Headed rivet
1
2
3
4
5
6
7
8
9
0
2
5
3
1
9
8
7
4
6
7
8
7
6
2
4
9
1
3
0
33
Combined clutch for tractors (special design)
Cover bracket
Flywheel plate
Pressure plate
Diaphragm spring
Coil spring
Insulating washer
P.T.O. plate
(with organic facing)
Main drive plate
(with cera-metallic facing)
Flywheel
Pivot pin
Fixing hole
Shipping bolt
P.T.O. adjusting screw
Link
Lever
Annti-rattle spring
Setting screw
Balance hole
Rivet
1
2
3
4
5
6
7
8
9
0
q
w
e
r
Achtung!
Shipping bolts must be removed after
fitting clutch to vehicle.
2
3
1
9
8
7
4
6
w
r
1
e
4
9
0
3
7
6
2
8
5
5
34
Single safety P.T.O. clutch with fixed
1
0
3
2
5
3
1
9
8
7
4
6
1
2
3
4
5
6
7
8
9
0
Cover bracket
Pressure plate
Coil spring
Fixed transmission damper
P.T.O. plate
Rivet
P.T.O. lever
Pivot pin
Adjusting nut
Flywheel
Balance hole
Hairpin spring
Rivet
35
Dual Safety P.T.O. clutch
Cover bracket
Diaphragm spring
Main drive plate
(with cera-metallic pads and torsion damped)
P.T.O. plate
(with organic facing and solid center)
Main drive lever
P.T.O. lever
Flywheel
Adjusting screw
Lock nut
Adjusting nut
Split wheel
Hairpin spring
Pivot pin
Coil spring
Balance hole
Rivet
1
2
3
4
5
6
7
8
9
0
q
w
e
r
e
1
w
9
r
6
3
4
2
1
0
q
8
7
5
q
36
LuK Clutch-Service-Tips
The following easy to use charts are provided to enable clutch problems to be easily
identified and make diagnosis simpler
Tangential straps damaged
Damaged levers/spring fingers
Cover assembly distorted
Driven plate distorted
Corrosion on friction material
Driven plate seized or sticking
on gearbox input shaft
Facing too thick
Facing material sticking
Torsion damper broken
Gear box snout damaged
Damaged spigot (pilot) bearing
Insufficient release travel
Excessive release travel
Driven plate seized to flyheel
or to pressure plate
Renew the clutch pressure plate
Check straps before fitting
Renew clutch pressure plate
Renew clutch pressure plate
Straighten driven plate
Clean the facing, remove all signs of corrosion
Remove burrs or renew plate
Remove all corrosion
Use correct grade of grease
Check parts are correct to application
Check parts is correct to application
Renew driven plate
Check driven plate for correct installation
Renew bearing
Check suitability
Lubricate snout
Renew bearing
Replace clutch cable
Bleed the system
Renew the release system
Check release system operation
Clean rust and corrosion from facing material
The clutch was dropped
Damaged on replacement
Incorrect assembly
Cover assembly not bolted down
evenly and sequentially
Check driven plate lateral runout (max 0.5 mm)
Vehicle not run for a long period
Damaged spline profile
Rust on input shaft
Incorrect grease used
Incorrect spline profile
Grease or oil contaminated
Driven plate incorrectly installed
Damaged release bearing
Incorrectly matched parts
No grease used
Worn
Incorrect clutch cable
or adjustment incorrect
Air in the hydraulic system
Release system damaged
A Clutch fails to disengage
Problem Cause Remedy
Pressure plate overheating
Clutch housing, levers or diaphragm
spring broken
Diaphragm fingers worn
Clutch facing worn out
Clutch facing contaminated
Uneven wear pattern on flywheel
side of facing material
Flywheel thickness incorrect
Gearbox snout damaged
Clutch cable heavy in operation
Release system heavy in operation
Renew clutch assembly
Renew oil seal
Follow correct installation procedures
Adjust pre-load
Adjust free play
Renew oil seals
Clean Flywheel
Re-machine flywheel
Machine bolting surface
Renew flywheel
Renew gearbox snout
Use correct lubricant
Check parts for suitability
Renew clutch cable
Check for correct cable assy
Renew bushes
Lubricate bearings or bushes
Thermal overload
Incorrect assembly
Broken diaphragm spring
Oil or grease contaminated
Incorrect installation
Excessive release bearing pre-load
No free play
Normal wear and tear
Incorrect pressure plate
Driver error
Oil seals leaking
Gearbox splines overgreased
Release bearing overlubricated
Badly worn flywheel
Incorrect machining of flywheel bolting surface
not machined to same dimension as running
surface
Non/incorrect lubricant
Damaged release bearing
Incorrect combination of bearing and snout
Clutch cable damaged
Incorrect cable
Damaged bushes on release arm or shaft
Bushes or bearing not lubricated
B Clutch slip
LuK Clutch-Service-Tips
37
Pressure plate uneven
Facing contaminated with oil
Facings contaminated with grease
Incorrect facing material
Facing damp
Difficult or hard operation
Air in the hydraulic system
Damaged gearbox snout
Engine/gearbox mountings
Engine not tuned/misfiring
Replace clutch cover
Install correctly
Renew oil seals
Replace driven plate
Renew driven plate
Renew release bearing
Check plate is suitable for application
Operate clutch to remove moisture
Fully inspect the release system
Check bearing/snout combination
Renew all suspect parts
Renew any suspect or damaged parts
Renew the snout and use correct grade
of lubricant
Replace mountings
Check engine for correct running
Broken or bent tangential straps
Distorted cover
Oil seals defective
Excessive grease on splines and release bearing
Incorrect plate fitted
Moisture penetrated facing
Clutch cable
Release lever bearings
Gearbox snout
Master or slave cylinder
Leaking or damaged master/slave
cylinders or pipes
Incorrect lubricant used
Incorrect or damaged mountings
Carburettor, fuel injection ignition timing
C Clutch judder
Bearing running eccentrically
to diaphragm fingers
No drive
Torsion damper broken
Release bearing defective
Spigot (pilot) bearing defective
Damaged damper spring breakout
Renew bearing
Renew pressure plate or driven plate
Fit correct driven plate
Fit correct driven plate
Renew bearing
Renew bearing
Renew driven plate
Bearing not centreing
Torsion damper incorrect for vehicles
application
Incorrect damper
Not rotating smoothly
Bearing seized
Incorrect driving habits
Wrong gear selection
D Clutch makes a noise
Incorrect pressure plate
Damaged gearbox snout
Release system bearings or bushes worn
Clutch cable damaged
Fit correct pressure plate
Renew release bearing
Check combination
Grease bearing and snout
Use correct grade of grease
Renew bearings and bushes
Lubricate where required
Renew cable
Check for suitability
Release load too great
Release bearing damaged
Incorrect combination
No grease used
Incorrect grease used
Bushes worn or not lubricated
Damaged release arm or shaft
Normal wear and tear
Incorrect cable fitted
E Clutch pedal is heavy in operation
38
LuK Troubleshooting and Service-Tips for Commercial Vehicles
Regarding malfunctions:
What is malfunctioning?
How was the problem
noticed?
How long has it existed?
Regarding wear:
Clutch mileage?
Is it the original
clutch?
Has the clutch
been abused?
Regarding usage:
Is the vehicle new?
Who drives it?
Regarding past repairs:
Have the clutch
and/or transmission
been repaired?
Start off by asking the customer these questions:
QUICK TEST Set the handbrake,
disengage the clutch and start
the engine, select fourth gear,
press the accelerator and slowly
engage the clutch
The engine should stall?
TEST DRIVE Disengage the
clutch while in 4th/5th gear,
press the accelerator and
engage the clutch
Does the engine speed up?
Insufficient friction between driven plate and flywheel/pressure plate
Excessive wear on driven plate/flywheel/pressure plate
Insufficient clamp load
ACTUATION Pedal mechanism,
Adjustment, Clutch cable,
Master/slave cylinders,
Hydraulic lines
DRIVE TRAIN Has no effect!
DRIVEN PLATE Oil/grease on
linings, Linings glazed or worn
thin
PRESSURE PLATE Pressure
plate overheated, Pressure
plate severely scored, worn
thin, diaphragm spring weak
FLYWHEEL Flywheel mating
surface scored, flywheel worn
thin
RELEASE SYSTEM Release
bearing, guide tube, release
fork, bearings
QUICK TEST Start the engine, shift into reverse;
Does the transmission make a noise when shifting gears?
ACTUATION Pedal mechanism,
adjustment, clutch cable, relea-
se fork rotating on its shaft or
broken, travel of master/slave
cylinders, master/slave cylin-
ders leaking, hydraulic lines,
fluid levels, air in the system,
clutch servo stroke too short
DRIVE TRAIN Hardy spicer
joints, drive shaft universal
joints/splines
Clutch fails to disengage Clutch slip
1. What are the particular symptoms? 1. What are the particular symptoms?
2. Which components might be defective? 2. Which components might be defective?
The pressure plate is not retracting or is dragging. The driven plate
is not free to rotate. Input shaft is seized in the spigot bearing.
3. What should be checked before clutch removal? 3. What should be checked before clutch removal?
4. What can be determined after removal? 4. What can be determined after removal?
DRIVEN PLATE Hub splines
rusted, linings rusted onto fly-
wheel/pressure plate, linings
fractured/torn off, excessive
lateral runout, lining backings
bowed, driven plate installed
backwards, torsional-vibration
damper springs have broken
loose, hub splines damaged,
incorrectly machined, or unlub-
ricated
PRESSURE PLATE Pressure
plate broken, leaf springs bent
or broken, diaphragm-spring
fingers severely worn, cover
distorted, diaphragm spring
bent or broken, inner surface
of diaphragm spring scored
due to excessively long travel
FLYWHEEL Has no effect!
RELEASE SYSTEM Release
bearing, release shaft seized
in its bearings, guide tube,
release fork broken or bent
SPECIAL CASE Driven plate
continues to rotate when the
clutch is disengaged because
the transmission input shaft
is seized in the spigot (pilot)
bearing
TWIN-PLATE CLUTCHES Are
the adjuster slides contacting
the flywheel?
COIL-SPRING CLUTCHES
Cam(s) or release-lever
mountings broken
PULL TYPE TWIN-PLATE
CLUTCHES Spacers have
slipped out of position
5. What might be causing the problem(s)? 5. What might be causing the problem(s)?
COMPONENT FAILURES Defective parts in the clutch itself?
In the release system?
ADVERSE EFFECTS CAUSED BY THE DRIVE TRAIN? Engine,
transmission, other drive-train components
EXTERNAL CAUSES Normal wear /Improper use/
Incorrect repair procedures
COMPONENT FAILURES Defective parts in the clutch itself?
In the release system?
ADVERSE EFFECTS CAUSED BY THE DRIVE TRAIN? Engine,
transmission, other drive-train components
EXTERNAL CAUSES Normal wear /Improper use/
Incorrect repair procedures
LuK Troubleshooting and Service-Tips for Commercial Vehicles
39
QUICK TEST Press the clutch pedal
Does it feel heavy?
Friction in the actuating mechanism, Friction
in the release system
ACTUATION Pedal mechanism, clutch
cable, release shaft, master/slave cylinders,
hydraulic lines, compressed-air booster
DRIVEN PLATE Has no effect!
PRESSURE PLATE Has no effect!
FLYWHEEL Has no effect!
RELEASE SYSTEM Wrong release
bearing, wrong/no grease used, release
shaft, release-shaft bearings worn,
damaged guide tubes, release fork
broken or bent
Clutch pedal is
heavy in operation
COMPONENT FAILURES Defective parts in
the clutch itself? In the release system?
ADVERSE EFFECTS CAUSED BY THE DRIVE
TRAIN? Engine, transmission, other
drive-train components
EXTERNAL CAUSES Normal wear /
Improper use/Incorrect repair procedures
QUICK TEST Locate the source of the
noise, Engage/disengage the clutch,
Is the noise coming from the vicinity of
the clutch?
TEST DRIVE Is the noise still there?
Rotating components are rubbing against
one another
Loose components
ACTUATION Pedal mechanism, clutch
cable, release shaft, master/slave cylinders,
hydraulic lines
ENGINE Engine tuning
DRIVEN PLATE Hub glazed, torsional-
vibration damper glazed, cover plate on the
torsional-vibration damper, torsion springs
have broken loose, hub splines worn
PRESSURE PLATE Diaphragm-spring
fingers worn, inner surface of diaphragm
spring scored due to excessively long travel
COIL SPRING CLUTCHES Cam(s) or
release-lever mountings broken
Spigot Bearing Noisy
FLYWHEEL Mating surface
RELEASE SYSTEM Release-bearing ball
bearings, release-shaft bearings, guide
tube, release fork
Clutch makes
a noise
Clutch
judder
1. What are the particular symptoms? 1. What are the particular symptoms? 1. What are the particular symptoms?
TEST DRIVE Does the clutch judder
(particularly under certain circumstances,
e.g., when reversing uphill)?
Erratic rotational motion of the crankshaft
or transmission input shaft, Erratic friction
between driven plate/flywheel/pressure
plate.
Pressure plate engages off-axis, clamp load
increases erratically, driven plate binding on
transmission input shaft
ACTUATION Pedal mechanism, Clutch
cable, Adjustment, Release shaft,
Master/slave cylinders, Hydraulic lines
DRIVE TRAIN Engine management, Engine
mountings, Transmission mountings, Prop
shaft, Drive coupling
2. Which components might be defective? 2. Which components might be defective? 2. Which components might be defective?
3. What should be checked
before clutch removal?
4. What can be determined after removal? 4. What can be determined after removal? 4. What can be determined after removal?
5. What might be causing the problem(s)? 5. What might be causing the problem(s)? 5. What might be causing the problem(s)?
DRIVEN PLATE Facing oily, facing greasy,
contact pattern incorrect
COVER ASSEMBLY Chatter marks, leaf
spring deformed, diaphragm spring bent,
cover warped
FLYWHEEL Surface incorrect
RELEASE SYSTEM Release bearing, release
shaft bearing, guide sleeve
Telefon: +49 (0)1 801-753-333
Telefax: +49 (0) 61 03-753-297
I NA-AS@Schaeffler.com
www.Schaeffler-Aftermarket.com
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Modes of Clutch Failure

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Modes of Clutch Failure

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Failure Diagnosis

LuKs guide to troubleshooting clutch-system

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