Fault Finding Guide Web

How to Use this Guide Contents
Clutches transmit power for gear shifting and stopping. EXEDY Corporate Profile.................................................................................. 4
Leaders in
EXEDY Worldwide Network............................................................................ 5
The essential qualities of a clutch are:
Cautions for Handling & Installation Preparation................................... 6
drivetrain
From
• Sure disengagement
• Smooth engagement Function of a Manual Clutch.......................................................................... 9 technology
Daikin to • Efficient gear change
Function of a Twin Plate Manual Clutch...................................................13
How to Get it Right the First Time..............................................................14
As a leading manufacturer
of drivetrain components,
EXEDY
• Performance and durability
Check Before Replacing.................................................................................15 EXEDY Corporation is
• Absorption of noise and vibration from the engine
Malfunctions of Clutch Discs........................................................................24 committed to providing
Our company pursues and power train.
Malfunctions of Clutch Pressure Plate Cover Assemblies..................34 superior products,
excellence in every Clutch efficiency depends on the make of car, the clutch technology and services.
Malfunctions of Other Clutch Components...........................................45
aspect of our operations. usage, as well as maintenance of the clutch. You must choose We bring decades of
Diagnosing Bearing Noises...........................................................................51
To better express this and fit the appropriate clutch to the vehicle and know how experience and a wealth
Malfunctions of Sports/Performance Clutches.....................................52
attitude, in August to install, use and operate the clutch correctly. Many clutch
Choosing the Correct Sports/Performance Clutch..............................56 of know-how to our efforts
complaints and problems are caused by factors other than the
1995 we changed our Function of Various Sports/Performance Products..............................58 to develop products that
clutch component itself — incorrect usage, faulty fitting and
name from Daikin How to Identify Your Clutch..........................................................................66 meet the needs of today’s
poor maintenance can all contribute to the fault. This manual
Manufacturing Co., Ltd. shows a wide range of clutch problems which can occur and Features of EXEDY Unity Type Dampener...............................................67 industries.
to EXEDY Corporation. lists the reasons for the problem. EXEDY has been supplying Driveline Misalignment..................................................................................68 Already at the top of
The new name was and servicing clutches in the market place for many years with Pull-Type Clutch Design Technology.........................................................69 our field, EXEDY is now
coined by combining advanced technological know-how and much experience gained moving forward toward
Torque Specifications for Flywheel & Pressure Plate...........................70
“Excellence” and from supplying the Original Equipment market. We are sure you new challenges in the
Hydraulic Clutch Pedal Adjustments.........................................................71
will appreciate both our service and our Fault Finding Guide
Dynamic” — terms that Please Read Before Installation...................................................................72 21st century.
fitting, operating and maintaining your clutch.
describe our qualities Beware of Imitations/Inferior Products....................................................73
as a corporation. At the Metric & Imperial Measurement Conversion Table..............................74
same time we adopted
a new corporate logo,
composed of three Getting it right the first time ... Industry Standard
curved lines that form
an ‘X’, representing With any clutch problem it is vital to diagnose the cause of clutch EXEDY’s product lines range from clutches for cars, industrial
society, customers and malfunction. Here are two examples in which merely replacing the machinery and construction machinery to torque converters
clutch would not have fixed the fault. and transmissions. Each product is manufactured under a
employees. The colors
For example... system that integrates all processes from development to
used in the corporate assembly and inspection, assuring the reliable products
logo - known as “excellent The Fault The Fix our customers have come to expect. Advanced, flexible
blue” and “dynamic Check hydraulics before production systems do more than meet customer
Difficult disengagement
replacing the clutch requirements in quality, cost and delivery time. It also
red” - now serve as our
Check thrust bearing for free travel results in products that offer the high levels of comfort and
corporate colors. Slipping clutch
operability today’s competitive market demands.
before replacing the clutch
DO NOT ASSUME ON ANY CLUTCH REPLACEMENT
2 EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com 3
EXEDY Worldwide Network
EXEDY Corporate Profile
1950 Incorporated as DAIKIN Manufacturing Co., Ltd.
1973 Established DYNAX Corporation in Hokkaido. RU

Moscú
2 Hungría
1975 Ueno Division Started in Mie. 1
China Estados
India Unidos
Jordania 10 7 Japón
Arabia Saudita 6
1977 Established DAIKIN Clutch U.S.A., Inc.(present EGP) 8
Vietnam
México
EAU
Tailandia
11 12
1981 Kawagoe plant started in Saitama. Kenia 5 Malasia
9 World 19 countries
Indonesia
3 Domestic 12 companies
1995 Changed Corporate name from
Production & Sales Overseas 24 companies
“Daikin Mfg. Co., Ltd.” to “EXEDY Corporation” Sales Australia
Others 4 Total 36 companies
Nueva Zelanda
1997 Listed on 1st Section of Tokyo Stock Exchange.
Aftermarket Group
EXEDY Globalparts Corporation
EXEDY Chongqing Co., Ltd.

1999 QS-9000 & ISO9001 Certified in March (Michigan, U.S.A.) (Chongqing, China)
8601 Haggerty Road South, No.4 Longjing Road, North New

Belleville, MI 48111, U.S.A. Economic Development Zone,
TEL: 1-734-397-3333 Chongqing, 401142, CHINA
2000 ISO14001 Certified in June FAX: 1-734-397-7300 TEL: 86-23-62924439
Expectation of the new head building FAX: 86-23-62900348
2001 Strategic Alliance with Aisin Seiki Co., Ltd.

EXEDY Clutch Europe Ltd.

(Cheshire, U.K.)
EXEDY (Thailand) Co., Ltd.

(Chonburi, Thailand)
Unit 2, Rokeby Court, Manor Park, 700/316 Moo 6, Bangna-Trad Road,

Runcorn, Cheshire, WA7 1RW, U. K. Tumbon Don Hua Roh, Amphur Muang,
2004 ISO/TS16949 Certified in June TEL: 44-1928-571850 Chonburi 20000, THAILAND
FAX: 44-1928-571852 TEL: 66-38-214-423
FAX: 66-38-214-422
EXEDY Australia Pty. Ltd.

P.T. EXEDY Indonesia

(Melbourne, Australia) (Karawang, Indonesia)
21 Fiveways Boulevard, Jl. Permata V Lot EE 3 Kawasan

Keysborough, Victoria 3173, Industri KIIC Karawang 41361 Jawa Barat,
AUSTRALIA Indonesia
TEL: 61-3-9701-5556 TEL: 62-21-89114666
FAX: 61-3-9701-5684 FAX: 62-21-89114568
Established July 1950

EXEDY New Zealand Ltd.
EXEDY India Ltd.

(Auckland, New Zealand) (Greater Noida, India)
151 Wairau Road Glenfield Plot No.L-4, M.I.D.C. Industrial Area,

President & CEO Haruo Shimizu Auckland, NEW ZEALAND Chikalthana, Aurangabad 431 210,
TEL: 64-9-444-0901 Maharashtra, no M.H.INDIA
FAX: 64-9-444-0903 TEL: 91-240-2484014
No. of Employees Consolidated 13,112 FAX: 91-240-2484403
As of 3/31/2011 Non-Consolidated 3,615 EXEDY Middle East Fzco

EXEDY India Ltd.

(Dubai, U.A.E.) (Aurangabad, India)
Consolidated US$ 2,36 Bil. P.O.BOX 18199, Warehouse No. Plot No.9, Udyog Kendra Industrial Area,
[Yen 196.4 bil.] ZE5 & ZE6 Jebel Ali Free Zone, Greater Noida, 201 304, U.P., INDIA
Sales (FY2010)
Jebel Ali Dubai, U.A.E TEL: 91-750-3131000
[$1=\83.15] Non-Consolidated US$ 1,3 Bil. TEL: 971-4-883-2244 FAX: 91-120-2397086
[Yen 109.0 bil.] FAX: 971-4-883-2500
EXEDY Guangzhou Co., Ltd.

EXEDY (Malasia) Sdn. Bhd.
(Guangzhou, China) (Negeri Sembilan, Malasia)
No.406 E-Area, Longfu Car PT 16748, Jalan Permata 1/5,

Accessories Centre, Hengfu Road, Arab-Malaysian Industrial Park 71800
Guangzhou, CHINA Nilai, Negeri Sembilan, MALASIA
TEL: 86-20-83489166 TEL: 60-6-7992988
FAX: 86-20-83489370 FAX: 60-6-7996388
EXEDY Latin America, S.A.

(Marbella, Panama City)
P.H. World Trade Center, Piso 3, Oficina 303

Marbella, Panama City, Republic of Panama
P.O. Box number 0832-00599
TEL: 507-395-7122/7123
FAX: 507-395-7124
Cautions for Handling & Installation Preparation
Four Main Functions of the Manual Clutch.
Function of a Manual Clutch

1. Function of transmitting the torque from the engine to the drivetrain.
2. Smoothly deliver the power from the engine to enable smooth vehicle movement.
3. Perform quietly and to reduce drive-related vibration.
4. Protect the drivetrain when given the inappropriate use. Given the situation, the
EXEDY clutch will fail when given the inappropriate use intern to protect the rest of
the drivetrain, similar to the function of an electric fuse.
Do not use Exedy OEM

replacement on a racing vehicle
Please do not use EXEDY OEM
products on modified cars.
Please use the sports clutch for
performance or racing cars.
Function of transmitting the torque from

engine smoothly.
The clutch consists of three parts with different roles.
When the clutch pedal is pressed, a cable or hydraulic piston pushes on the release fork, which
presses the throw-out bearing against the middle of the diaphragm spring. With the spring
pushed, the clutch disc is then disconnected from the rotating flywheel that is attached to the
engine. When the pedal is released, the disc will engage contact with the flywheel and transmit
the torque from the engine to the rest of the drivetrain.
CLUTCH DISC
Engine torque can be cut off and transmitted by engaging or disengaging from the flywheel.
Twin Plate Manual Clutch
Function of a Twin Plate Manual Clutch

CLUTCH COVER
Clutch cover is to support clutch rotating system and transmit the engine
torque by pushing the clutch disc.
FLYWHEEL SIDE CLUTCH DISC
TRANSMISSION
SIDE CLUTCH DISC
ATTENTION:
Please make sure to break-in the clutch for 500
miles or more with easy street driving.
(No abuse, more shifting not only mileage)
Good Fitting Practice ...
Check Before Replacing

Noise Driveable
How To Get It Right The First Time
Installing your new EXEDY/Daikin Clutch Page 18 Causes

1. Getting it right the first time. It is vital to diagnose the cause of clutch malfunction before and Solutions
clutch replacement, i.e. check hydraulic system - bearing free travel - clutch cable, oil leaks and
check for any signs of red dust when old clutch is being removed. Any or all of these problems
must be corrected before installing new clutch.
•Not depressing clutch pedal
2. Ensure clutch supplied is correct for application. If you’re unsure, consult your EXEDY/Daikin
Clutch Catalogue or your supplier, as fitting a clutch to the wrong application will void the
5A, 5B, 5C, 5E
warranty.
3. Flywheel must be resurfaced or warranty void and check pilot bearing or bush and replace
if necessary.
Idling •Depressing clutch pedal
5C, 5D, 5F
4. Before fitting, check clutch for any shipping damage. Next, check that clutch disc slides freely
on gearbox shaft and then clean shaft splines. Lightly grease the shaft splines with high
melting point grease. Always ensure bell housing is degreased and is free of dust and that
fibres from the worn clutch are removed.
5. Check the clutch release fork for cracks, check the clutch cable for stretch signs and
check the release bearing gear box quill/gear box main drive nose cone bearing slide for
•Engagement
5G
any wear. Always lightly grease this part where the bearing slides. This will allow smooth
sliding of the bearing carrier. Always work the fork forward and backwards after installing •Open throttle
bearing on the quill.
(Acceleration)
6. Place the clutch cover pressure plate assembly over the clutch disc, after checking that the
disc is the right way around and the hub section of the disc does not foul on the casting of Starting
the clutch cover assembly or the flywheel. A suitable clutch aligning tool will ensure correct
alignment, assist in ease of installation and avoid spline damage. (Burrs on splines are a major
cause of difficult gear disengagement). Ensure pressure plate dowels are aligned to the cover.
Tighten bolts is a diagonal pattern and never use air tools to install a clutch cover assembly.
•Engagement 5H
7. Re-fit gear box, taking care not to bend the clutch disc. Never hang the gear box off the clutch
disc or use any force to align gear box shaft. •Acceleration,
8. Check all bell housing dowels are in correct position and tighten bell housing bolts.
Ensure there is no dirt or foreign material between the mating surfaces of the engine Driving Deceleration 5I
and the bell housing.
9. Perform any clutch adjustment only to vehicle manufacturer’s specifications.
•Depressing
5J
10. Always check the clutch cable if you are unable to obtain disengagement when a new clutch is
fitted. Start off your check process be replacing the cable and checking hydraulic system.
11. Road test vehicle and never abuse a newly fitted clutch. Allow 1000mi run in and
Others clutch pedal
always adjust free travel on your new clutch at 1000mi and 3000mi. Thereafter adjust at
every 10,000 mi.
Observe the sure signs of a worn clutch when removing.
1. Red dust.
Warning: Do not use EXEDY/Daikin clutches in any situation where engine RPM’s may
exceed manufacturer’s specifications — a pressure plate could explode 2. Broken side plates or springs
unexpectedly causing serious injury or death to vehicle occupants and 3. Damaged torque stopper pins
bystanders. Clutch cover and bell housing will not protect against exploding 4. Clutch disc with broken segments and broken friction material.
pressure plates. Refer Application Catalog correct fitment.
5. Broken or worn release bearing quills/gear box nose cone bearing slide.
Something wrong with clutch pedal Page 20 Causes Something wrong with gear shift lever Page 22 Causes
and Solutions and Solutions
•Before engine
Engine Running 7A
start 9A
Heavy effort Unable to shift
•Whilst engine running 9B
Pedal not returning from the bottom 7B Heavy gear shift effort 9B
•Noise on all gears
•Shortly after
replacement 7C Rasping sound •Noise on reverse gear 9B
Engage, during operation •Noise on particular
disengage at 9C
•After a while 7D
high position Vibration on shift lever 9D
•Shortly after
replacement 7E, 7F
Disengage at
low position •After a while 7F, 7G Unable to drive Page 22 Causes
and Solutions
No acceleration •Burning smell 9E

•Disappear Slow down
Vibration when vibration when 7H •Shortly after
foot on pedal depressed
Whip back and force replacement 9F
7I
harsh engagement •After a while
9G
No free play/A lot of free play
No drive gear •Noisy clutch 9H
Wobble 7J
Movement with
depressing clutch pedal
•Heavy effort 9I
Causes and Solutions (Noisy Clutch)

No improvement
Check before replacing the clutch Check after removing transmission

• Confirm if noise disappears when the Clutch pedal is depressed.
If the noise disappears when clutch pedal depressed, this is an idle gear rattle due to use of non • Check clutch compatibility.Replace with suitable clutch, if not compatible.
5A specified, low viscosity oil.

Exchange with specified transmission oil.
• Check backlash or free play at the movable part of release fork.Adjust or repair according to service manual.
• Check wear on main drive shaft and spline hub.
Worn out parts shall be replaced with new one.
• In case of being backlash or looseness in control systemcheck installation • Check damage on clutch cover or clutch disc.
Clutch may have failed if excessive force has been applied during installation.
5B • Abnormal idling RPM. Heavy vibration and rumblings.

Jack up engine and adjust to the normal idle speed.
• Removal of hold down bolts. Failed parts shall be replaced with new one.
• Non removal of hold down bolts (hold down bolt type only) • Failed parts shall be replaced with new one.
Check if the Clutch Cover has red colored painted bolts through inspection hole.
5C
Clutch may be failed if excessive force has been applied during installation.
• Parts are damaged by excessive force during clutch replacement.
Check parts after removing transmission. • Check whether there is an interference mark on clutch cover and clutch disc.
Failed parts shall be replaced with new one.
5D • Interference between clutch disc and clutch cover due to over stroke.
Adjust clutch pedal free play. • Check bearing on transmission side whether there is backlash.
Repair according to service manual.
• Reconfirm whether the noise comes from the Clutch
5E • Abnormal bearing on transmission.
Check bearing after removal of transmission.
• Check damage and direction of a release bearing.Replace with new one, if damaged.
• Check backlash on a pilot bearing.Replace with new one, if failed.
5F • Malfunction of release bearing or pilot bearing.

Check if Release Bearing was replaced with new one during Clutch replacement. • Check tightness of flywheel bolts/ clutch cover bolts.Replace with new one, if damaged.
5G • Interfering noise by jolting of driveline under driving torque.

Check the drivetrain, and engine mount installations for any signs of breakage and cracking.
• Check whether diaphragm finger tips were even.
Remove clutch cover, then reinstall same cover and tighten bolts. When you install the clutch cover, tighten
bolts temporary by hand, then torque down in correct diagonal sequence one by one.
• Does release control system operate smoothly? • Check whether grease flew out on a clutch disc.
Inspect clutch booster itself, grease up at movable part.
5H
No adequate friction or noise. Replace with new clutch disc.
• Check wear condition of clutch disc.
Check wear condition through inspection hole or release fork area. • Reconfirm compatibility.Replace with adequate clutch, if not compatible.
• Check whether grease flew out on a clutch disc. Replace with new one, if greased.
• Driving gear rattle due to unspecified low viscosity of oil. Deteriorate function of noise control and vibration control resulted in noise. Replace with new clutch disc, if
5I Exchange specified transmission oil.

• Backlash or looseness on control system causes noise. Check installation.
greased.
• Check backlash or free play at the joint of release fork.Adjust to manufacturer’s specification.
• Grease up at movable part of clutch pedal, release fork and lever. • Inspect slide portion at release bearing/fork. Grease up.
5J • Inspect clutch booster.
In case of failure of clutch booster, repair according to the service manual.
• Replace with new parts, if damaged.
• In case of a failure without known cause, please apply a request that there be an investigation based on warranty certificate.
Followings, however, are not eligible
1. Failure by wear or aging variation
2. 90 days or 3,000 miles under normal driving condition after installation
Causes and Solutions (Abnormal on clutch pedal)

No improvement

7A • Is a clutch booster normal? Inspection according to service manual.
• Does control system operate smoothly? Adjust or grease up.
• Inspect slide portion at a release bearing/fork, a transmission retainer, etc. Grease up.
• Is the clutch pedal height or free play appropriate? Replace damaged parts, if failed at slide portion.
Adjust pedal free play and rod projecting amount according to a service manual. Grease up periodically, if fixed intervals is specified by manufacturer.
7B • Is a piston firmly fixed to a release cylinder?
• Is there any oil leakage from release cylinder, master cylinder or clutch pipe line?
In case of leakage, overhaul and repair.
• Check failure of release bearing, or direction of it.
Replace with new parts, if failed.
• Is there air in clutch line? work out air-bleeding. • Check compatibility of clutch cover.
If you use unspecified clutch, clutch pedal effort becomes heavier or clutch
• Is the clutch pedal height or pedal free play appropriate? pedal does not return from the bottom.
7C Adjust pedal free play and rod projection amount according to a service manual.
• Check whether the release cylinder operates properly..
• Is the clutch pedal height and free play adequate? If you reduce pedal free play excessively,
the release bearing does not return and it may result in a change of engagement point in use. • Check oil leakage from CSC, Concentrated Slave Cylinder, or smooth movement.
7D
Adjust pedal free play and rod projection amount to manufacturer’s specification. Replace with new components, if failed.
• Does a driver have a habit to drive with his foot on a clutch pedal or to use semi-disengagement • Check wear or failure on the clutch cover and the clutch disc.
frequently?Check wear condition on a release fork through inspection hole. There is a Replace with new components, if failed any.
possibility to wear clutch disc prematurely. Educate a driver not to put his foot on a clutch pedal during driving.
• Is the clutch pedal height or free play appropriate?

7E Adjust pedal free play or rod projecting amount according to a service manual
Check release cylinder whether it operates properly. • Check distortion on the clutch disc or cover.Replace with new if distorted.
• Check oil leakage from a release cylinder, master cylinder and clutch line. • Check the backlash on a release fork/lever.Adjust or repair according to a service manual.
In case of leakage, overhaul or repair it according to a service manual. • In case of lever type clutch cover, is it used with lever height adjustment?
It is not necessary to adjust lever height, because it is adjusted properly. Adjust it by release control system.
7F • Is there air in clutch fluid line?
Bleed hydraulic system.
• Is there any failure on a release fork such as deformation?
Remove a transmission and replace it. • Inspect deformation and excessive wear condition of release fork and pivot etc.
Replace with new components, if damaged.
• Does a driver have a habit to drive with his foot on a clutch pedal or to use semi-disengagement
7G
frequently?
Components will be over heated and distorted. It results in difficult to disengage gear. • Frequent usage of semi-disengagement makes a clutch disc distort, and results in a change of disengagement
Overhaul according to a service manual. point. Replace with new one, if damaged.
Educate a driver not to drive with his foot on a clutch pedal or not to use it in semi-disengagement frequently.
7H • Shortly after replacement the position of a release bearing is unstable and results in vibration.
Depress clutch pedal a couple of times to fit.
7I • Is the clutch pedal height and free play adequate?

Adjust the pedal height and free play to manufacturer’s specification.
• Check whether diaphragm fingers or levers are uneven.
Remove clutch cover, then reinstall same one and tighten bolts.
7J • Check looseness of pedal installation, and adjust free play. When you install the clutch cover, tighten bolts temporary by hand, then torque down in correct diagonal
Replace with new one, if failed. sequence one by one.
Causes and Solutions (Shifting & Driving)

No improvement
9A • Is there any problem with installation of clutch cable?

Check installation of shift control system. • Check the backlash on a release fork and lever.
• Check the failure and direction on a release bearing.

• Check scratches on spline hub.
• Possible difficult to disengage gears. Is the pedal height or free play adequate?
• Check whether pilot bearing rotate freely.
Adjust the pedal free play and rod projecting amount according to a service manual.
9B
Always replace with new components, if failed.
Check the return of piston of release cylinder.
• Is there any problem with installation of clutch cable? • Check oil leakage or smooth movement on CSC, Concentrated Slave Cylinder.
Check installation of shift control system. Always replace with new components, if failed.
9C • Failure of transmission, if it is a particular gear. (except reverse gear)

Check a transmission.
• Remove a clutch and replace with new parts, if failed.
Check a release bearing, a pilot bearing, a release fork and a pivot, when you
replace a clutch.
Pedal height and free play shall be adjusted, and hold down bolts and set wire
9D • Is there any problem with installation of clutch cable?
Check the backlash of shift control system.
shall be removed as well.
• Is the pedal height or free play adequate? • Inspect slide portion at release bearing/release fork.
Adjust the pedal free play and rod projecting amount according to a service manual. Grease up
9E Check the return of piston of release cylinder.
• Remove hold down bolts. (Hold down bolts type only)
• Check oil or grease on a clutch disc.
Replace with new clutch disc, if contaminated with oil or grease.
Check the red painted hold down bolts through inspection hole.
9F • Does a clutch pedal operate smoothly?

Check a release fork and lever whether they operate smoothly. • Check a pressure plate whether it is shiny ground friction surface.
If a driver put his foot on a clutch pedal during driving, the clutch performance is
deteriorated and results in bad semi-disengagement performance.
• Interference noise by driveline under heavy load.
9G Check breakage, cracks, installation of engine/transmission mount, also check the backlash on a
drive train.
• Remove the hold down bolts or set wiring.
Replace it, if failed.
• Remove hold down bolts. (Hold down bolt type clutches only) • Inspect slide portion on a release bearing/ fork. Grease up.
9H Check the red painted hold down bolts through inspection hole.
• Check the installation of shift rod and wiring, also smooth movement of a release fork and lever.
• Check the deformation of strap plate and clip, broken parts between gap as well.
• Is the clutch pedal height and free play adequate? Replace it, if failed.
9I
Adjust it according to a service manual.
• Check the backlash on a release fork/ lever
• Check oil leakage from a release cylinder, master cylinder and clutch line.
Adjust or repair it according to a service manual.
Overhaul or repair according to a service manual.
Malfunctions of Clutch Discs

PROBLEM: Contact mark on the teeth of spline and the end
of hub.
Symptom: Difficult to disengage gears. PROBLEM: Damaged facing material.
Cause: Excessive force to fit a main drive shaft Symptom: Difficult to disengage gears.
causes this problem during reinstallation of Cause: Clutch disc has been dropped possibly during
transmission. installation or damaged in transit. Bulged clutch
Solution: During the installation of transmission, align facing to contact flywheel causes this problem.
drive line; Solution: Always check before installation that is intact.
-height
-angle Treat parts carefully.
-spline teeth
then fit without excessive force.
PROBLEM: Oily facings.

PROBLEM: Burrs at the end of hub due to uneven wear on Symptom: Slipping clutch/shuddering juddering clutch.
the spline teeth.
Cause: Excessive grease or low viscosity grease causes
Symptom: Difficult to disengage gears. this problem.
Cause: Misalignment between engine crank shaft Melted grease on friction material will affect the
and transmission main drive shaft causes this friction coefficient of disc facing causing facing
problem during installation of transmission. failure.
Solution: 1. Replace deteriorated pilot bearing or bush. Solution: Lightly grease spline, wipe off excessive grease
after tentative installation and ensure there is
2. Reinstall parts after removal of contamination smooth sliding of clutch disc on main drive shaft.
or scratch on the mating surface of bell housing.
Use grade of grease specified by vehicle
manufacturer.
PROBLEM: Broken facings.

PROBLEM: Damaged torsion springs.
Symptom: Slipping clutch/Shudder/Judder/Noisy clutch
Symptom: Unable to disengage gears/Noisy clutch. unable to drive.
Cause 1. When engine torque is higher than clutch Cause: Following factors lead to high temperature of
torque, this misapplication causes springs to friction surface, resulting in this problem.
deteriorate. 1. Driving with a foot on a clutch pedal
2. Misalignment between engine crank shaft 2. Overloading vehicle
and transmission main drive shaft causes this 3. Improper starting gear
problem during installation of transmission.
4. Clutch pedal height or free play maladjustment
Solution: 1. Choose and fit appropriate EXEDY clutch to 5) Oil/grease contamination.
suit the application.
Solution: 1.~ 3. Driver education.
2. Reinstall deteriorated pilot bearing or bush 4. Adjust pedal free play according to service
parts after removal of contamination or scratch manual.
on the mating surface of bell housing.
*Do not over grease input shaft or disc during installation.
Damaged torsion springs

PROBLEM 1: Stripped out or wore teeth on spline.
Problem: Oily Facings.
PROBLEM 2: Cushion spring steel segments separated from
hub area. Symptom: Slipping clutch/shuddering/juddering clutch.
Symptom: Noisy clutch/unable to drive. Cause: 1. Faulty main drive oil seal.
Cause: Misalignment between engine crank shaft and 2. Faulty rear main bearing oil seal.
transmission main drive shaft during installation Solution: 1. Replace clutch disc.
of transmission.
2. Replace faulty oil seals.
Excessive force to fit main drive shaft causes this
Stripped Out Spline problem during reinstallation of transmission.
Solution: During the installation of transmission, align
drive line,
-height
-angle
-spline teeth
then fit without excessive force.
Exchange the deteriorated pilot bearing or bush Problem: Difficult gear engagement/broken rubber
parts after removal of contamination or scratch dampeners.
on the mating surface of bell housing.
Symptom: Noisy, no disengagement (rubber torque
stopper type clutch disc).
Separated clutch disc assembly Cause: 1. Use of inferior or imitation clutch disc.
2. Clutch wound past torque capacity.
3. Inferior rubber compound.
Solution: 1. Fit genuine EXEDY/Daikin clutch.
2. Driver education.
PROBLEM: 1. Crashing noise in gear box, non release.

2. Warped and bent clutch disc.
SYMPTOM: Difficult gear change.
CAUSE: 1. Hanging of gear box during installation.
2. Not aligning clutch disc and forcing main drive
into the spline, therefore, bending the clutch disc
hub towards the engine as seen in photo. PROBLEM: Power not transmitting to drive train because
Note: Hanging the gear box during installation of broken facings.
pulls the clutch disc hub towards the gear box. SYMPTOM: No drive, noisy clutch.
3. Driver resting foot on clutch pedal causing
CAUSE: Parts of the disc friction material are broken from
clutch slip due to clutch being in a semi
rivet along with part of the cushioned segment.
disengaged position. This has caused extreme
This is due to down shifting of gear i.e. the speed
heat which has warped the disc.
of the vehicle at the rear wheels was travelling
SOLUTION: 1. Do not hang gear box during clutch faster than the engine RPM, when gear was
installation. Always use a clutch aligning tool. changed down.
2. Do not force gear box into clutch disc spline. SOLUTION: Driver education.
3. Driver education/check free travel.

PROBLEM: Broken facing of clutch disc on clutch cover
assembly pressure plate side.
SYMPTOM: Broken clutch facings flywheel side.
SYMPTOM: Noisy clutch/slipping clutch.
PROBLEM: Clutch slips, does not disengage.
CAUSE: 1. Improper driving practice; down changing
CAUSE: 1. Overloading vehicle.
gear constantly.
2. Clutch disc has been replaced but not clutch
2. The speed of the vehicle is actually higher than
pressure plate cover assembly.
of the shifted to gear.
3. Lack of applied load (inefficient diaphragm
3. The gear box and drive train revolutions are
spring pressure or coil spring pressure).
turning faster than the speed of the engine at the
SOLUTION: 1. Do not overload vehicle. time: sudden clamp damaged the facings.
2. Replace with complete clutch kit. 4. Excessive grease on the transmission input shaft.
SOLUTION: Driver education. Proper fitting practice.
PROBLEM: No drive, power not transmitted because of

broken segments on clutch disc.
SYMPTOM: Sudden clutch failure.
CAUSE: Cushion spring steel segments uniformly
separated from hub area due to:
PROBLEM: Clutch disc completely ruined.
1. Faulty or worn pilot bearing or bushing.
2. Hanging gear box during installation. SYMPTOM: Sudden clutch failure.
3. Dirt or chips between the mating surfaces of CAUSE: Clutch disc fitted incorrectly i.e. back to front.
the engine bolt up areas.
4. Gearbox/transmission lock up. (i.e. Gear tooth SOLUTION: 1. Always check clutch disc on flywheel for
jam). fouling before installation.
SOLUTION: 1. Check pilot bushing or bearing and replace if 2. Always refer to installation procedures on
necessary. Align gear box and use the assistance EXEDY/Daikin packaging.
of a transmission jack and always clean mating
surfaces before installation.
2. Check gear box for metal fragments than
remove and repair as necessary.
PROBLEM: Premature wear cerametallic button type clutch

disc. PROBLEM: Damaged torsion springs.
SYMPTOM: Slipping clutch. SYMPTOM: Gear box rattle/noisy clutch - diesel applications.
Other descriptions of problem are: jarrah noise,
CAUSE: Bedding-in procedure not observed for gear box rollover noise or tick over noise.
cerametallic buttons.
CAUSE: When engine torque is higher than clutch torque
SOLUTION: Drivers education; observe bedding in this causes springs to deteriorate. This is due to
procedure. Due to the weight of this type of the very different characteristics in design of this
disc it takes longer for the rotating clutch to particular clutch disc.
slow down while clutch cover assembly is in a
separation position away from the clutch disc. SOLUTION: Choose and fit and appropriate EXEDY/Daikin
Clutch must be depresses a few seconds longer clutch to suit this application (e.g. silent type
whilst shifting gear specifically when there is no design or LTD design).
clutch brake attached to the system.
PROBLEM: Burst clutch disc/no transmitted power.

SYMPTOM: Clutch slip.
CAUSE: 1. The clutch was engaged while coasting PROBLEM: Different number of spline on main drive to
downhill causing the facings to burst through those on clutch disc/diameter of spline incorrect.
extreme shock.
SYMPTOM: Unable to fit clutch disc on main drive shaft.
2. Gear being shifted down when the vehicle engine is revving
lower than the transmission ratios, resulting in excessive RPM CAUSE: Careless fitting practice. The right clutch disc
at the driveline end. This is beyond the capacity of the burst was not checked on main drive spline before
strength specifications of the friction material. installation.
3. Lock of free travel caused by faulty clutch slave cylinder
or air over hydraulic system (common in Japanese truck SOLUTION: 1. Always refer to EXEDY/Daikin packaging
applications). With a new clutch kit installed keeping in mind instructions before installing clutch.
the diaphragm tips/release lever tips are further down due to 2. Try clutch disc on main drive for smooth sliding
the thickness of the new clutch disc. The slave cylinder piston before installation.
will now be operating further towards the end of the cylinder
where it has not worked for some time, depending on
adjustment and travel. This area in the cylinder may possibly
be corroded, again keeping in mind that brake fluid is a
hygroscopic liquid, which is very absorbent of moisture and
moisture corrodes and could result in the piston jamming
and not returning, therefore, causing the release mechanism
to activate the clutch in a semi disengaged position.
The above corrosion problem would also apply to the air
canister in the air over hydraulic assist system. A partly PROBLEM: Crashing in all gears/damaged and
disengaged clutch generates extreme heat affecting the burred splines.
clamp load of the diaphragm spring/coil spring ultimately
causing the friction material to burst. This is always indicated SYMPTOM: Difficult to disengage gears.
by the blue and burnt coloring on the pressure plate cover CAUSE: Defective pilot bearing or bush. This causes
assembly casting and clutch disc. A strong burnt smell is also angular wear on the spline teeth, not allowing
noticeable. the clutch disc to slide on the spline teeth. It also
4. Driver resting foot on clutch. causes the clutch disc to possibly stick on to the
5. Lack of free travel and proper adjustment. flywheel or not separate from the clutch cover
6. Wrong differential speed selected to match with chosen pressure plate assembly. This results in poor
gear (trucks with 2 speed differentials.) separation, no disengagement.
SOLUTION: 1. Driver education for 1, 2, 4, and 6. SOLUTION: Fit new pilot bearing or bush.
2. Check clutch release mechanism, air system
and hydraulics for 3.
3. Adjust clutch to manufacturer’s specifications
for 5.
PROBLEM: Noisy and cannot transfer power/splines

completely disintegrated.
SYMPTOM: No drive.
CAUSE: 1. Clutch disc not tested on spline before
PROBLEM: Damaged facing material. installation.
CAUSE: 1. Clutch disc has been dropped possibly during 2. Missing spigot/pilot bearing or bushing.
installation or;
SOLUTION: 1. Always check clutch disc for smooth sliding on
2. Damaged in transit. spline.
SOLUTION: Always check before installation that 2. Check and replace spigot/pilot bearing of
facing is intact. Replace clutch disc. bushing. (Mini UK and Europe: Check primary
gear for worn bushing; if worn replace).

PROBLEM: Clutch drag leading to total clutch failure. Signs
of red dust on clutch disc as seen in photo.
PROBLEM: Torsion dampener stopper springs thrown SYMPTOM: Clutch inoperative.
out of side plate/stop pins worn.
CAUSE: Severe misalignment between the mating
SYMPTOM: Noisy clutch/unable to engage or surfaces of the bell house and the rear of motor.
disengage gear.
SOLUTION: 1. Refer misalignment tips.
CAUSE: 1. Improper driving practice i.e. “dropping” the 2. Engine and gearbox modifications where
clutch whilst engine is turning at extremely high mating surfaces are not parallel or the engine
revolutions. and gear box do not mate at an absolute centre
2. Down changing of gears i.e. 5th gear to 2nd line are to be rectified.
gear by low speed/high driving gear method. 3. Metal dust cover plates overlapping each other
3. Wear on the stop pins indicates the clutch during installation must be avoided.
plate has been wound past specified torque
loading. This has the same affect on the springs.
4. Misalignment.
SOLUTION: 1. Driver education.
2. Refer misalignment tips
3. Vehicle used for performance driving. It
is advisable to use clutch disc with higher PROBLEM: Torque stopper springs broken. Difficult gear
stopper torque capacity. Refer EXEDY/Daikin engagement which may lead to clutch failure.
Performance/Sports Clutch listings.
SYMPTOM: Noisy clutch with vibration.
CAUSE: 1. Misalignment between engine crank-shaft
centre and gearbox main drive.
2. If the torsion springs are damaged along with
the torque stopper pin then it is evident that the
clutch has been wound past its torque capacity.
SOLUTION: 1. Refer misalignment tips.
Problem: Wrong type of lubrication on input shaft spline.

Symptom: Clutch shudders/judders and/or slips.
Cause: 1. On this example the wrong grade of grease
Problem: Melted grease on clutch disc side plate.
was used, affecting the friction coefficient of the
disc material. Symptom: Clutch shudders/judders and/or slips.
2. Over greasing of transmission input shaft Cause: 1. Excessive grease on transmission input shaft.
during installation. 2. Melted grease on friction material will affect
Solution: 1. Use specified grade of grease of vehicle friction coefficient of disc facing.
manufacturer (high melting point grease). Do Solution: 1. Lightly grease spline, wiping of excessive
not use anti-seize. grease and ensure there is smooth sliding of
2. Replace clutch disc with new disc unit. clutch disc on main drive.
2. Replace clutch disc with new disc unit.
3. Proper installation practice.
3. Use only high melting point grease.
Malfunctions of Clutch Pressure Plate Cover Assemblies

PROBLEM: Excessively worn diaphragm fingers.
SYMPTOM: Pedal graunch sometimes described as erratic
feeling when depressing clutch pedal with PROBLEM: Excessive wear on diaphragm tips.
engine running but OK when not running/notchy
clutch pedal. Symptom: Difficult to disengage gear/ Noisy clutch.
CAUSE: 1. Eccentricity between the axis of rotation of the Cause: 1. Misalignment between the axis of release
clutch cover pressure plate assembly and that of bearing and clutch cover causes this problem.
the clutch thrust bearing. Wear on the fulcrum inside of clutch cover along
with the wear on lever tips makes less pressure
2. Inferior clutch thrust bearing (not self plate lift, results in difficult to disengage gear. 1) Excessive wear on diaphragm tips
centering type).
2. Improper direction of release bearing causes
3. Worn release bearing sleeve carrier or clutch one of abnormal wear.
fork.
Solution: 1. Replace the deteriorated bearing or bush
4. Lack of free travel. parts. Reinstall a transmission after removal of
SOLUTION: 1. Refer misalignment tips. contamination or scratch on the mating surface
of bell housing. Replace the deteriorated release
2. Fit proper self centering bearing. bearing and front cover.
3. Rectify release mechanism and align. 2. Install a release bearing in correct direction.
4. Adjust free travel to manufacturer’s
specification.
2) Excessive wear on diaphragm tips
PROBLEM: Diaphragm fouled on clutch disc. Crashing in PROBLEM: Burst pressure plate casting.
gear and unable to obtain clutch adjustment.
SYMPTOM: No disengagement.
SYMPTOM: Difficult to engage/disengage gear.
CAUSE: 1. Over revving of engine that has exceeded
CAUSE: 1. Flywheel depth or step incorrect. vehicle manufacturer’s specifications.
2. Clutch thrust bearing fallen off quill end/gear 2. Over heating of casting due to constant
box nose cone slide. abuse of clutch. The main spring has weakened
through extreme influence of heat.
3. Clutch disc too thick.
3. Inferior part manufacture.
4. Incorrectly adjusted (overthrow of clutch
mechanism). SOLUTION: 1. Driver education.
SOLUTION: 1. Check flywheel depth or step height. 2. Do not use EXEDY/Daikin covers where engine
has been modified to excess manufacturer’s RPM
2. Check for wear on release bearing quill shaft/
specifications.
gear box nose clone slide.
3. Use EXEDY/Daikin specified sports clutch.
3. Check clutch disc thickness.
Refer to EXEDY/Daikin Catalog or EXEDY/Daikin
4. Refer to clutch adjustment procedure or Sports Listings where covers are manufactured
replace cable. with nodular iron castings.

PROBLEM: Oil or grease contamination on friction surface.
PROBLEM: Hold down bolts still in cover assembly.
Symptom: Slipping clutch/Judder.
Symptom: Clutch slipping/Noisy clutch.
Cause: Excessive grease or low viscosity grease causes
Cause: Clutch cover pressure plate assembly hold down this problem.
bolts to assist ease installation not removed. Melted grease on friction material affected
Solution: Remove hold down bolts painted in red. (Do not friction coefficient and caused slipping or judder.
remove clutch lever adjustment nuts which are Solution: Lightly grease spline, wipe off excessive grease
not painted in red)
after tentative installation and ensure there is
smooth sliding of clutch disc on main drive shaft.
Remove hold down bolts Grease on friction surface
PROBLEM: Mirror finish on pressure plate friction surface.

Symptom: Judder. PROBLEM: Discoloration on friction surface and/or clutch
Cause: 1. Friction surface may be ground by worn facing cover.
fibers as abrasive compound, if you keep clutch
Symptom: Slipping clutch.
slipping continuously i.e. hill start. It may cause
judder because of too good surface to become Cause: Extreme friction surface temperature rise and
mirror finish. slips under extreme clutch operation. This may
2. Clutch slave cylinder corroded or worn and cause discoloration of clutch.
piston not returning freely.
Solution: Driver education not to activate the clutch in
Solution: 1. Driver education not to activate the clutch in excessive semi disengagement position.
an excessive semi disengagement position. Friction surface, cover discoloration
Mirror finish on pressure plate 2. Replace slave cylinder..
PROBLEM: Burst pressure plate casting.

Symptom: No drive/Noisy clutch.
PROBLEM: Warped clutch cover assembly by reuse.
Cause: 1. Over revving of engine that has exceeded Symptom: Clutch drag.
manufacturers’ specifications.
Cause: Insufficient contact due to warped pressure
2. Overheating of casting due to constant abuse
plate. Only clutch disc was replaced which
of clutch. The main spring has weakened through
extreme influence of heat. caused partial contact on friction surface and
slipped during heavy load condition.
Solution: 1. Do not use covers where engine has been
modified to excess manufacturer’s rpm Solution: Always replace a clutch disc, a clutch cover and
specification. a clutch thrust release bearing when replacing Pressure plate heat distortion
clutch system.
2. Driver education not to activate the clutch in
Breakage of pressure plate excessive semi disengagement position.

Problem: 1. Vehicle vibrates/shakes when clutch is being
released, at take off.
Symptom: Clutch shudder/judder/chattering.
Cause: 1. Flywheel not even/warped.
2. Deep scoring indentations from previous worn
clutch.
Solution: Always resurface flywheel before installing new
clutch. Refer to figure below.
50% 25%
PROBLEM: Worn clutch disc facing fibres and dirt lodged between
diaphragm spring and clutch cover housing causing loss
Belled out surface might look smooth but uneven
of clamp load.
SYMPTOM: Slipping clutch and clutch drag.
CAUSE: 1. Bell housing not degreased and cleaned. Careless
installation of new clutch. Problem: Highly glazed to a mirror finish
pressure plate cover assembly
The new clutch disc has not worn but the fibres that casting/red dust on clutch
have become lodged in the new clutch cover are that components.
of the previously worn clutch. It is a requirement due
to ventilation designs that the bell housing area be free Symptom: Shuddering/juddering clutch.
from old fibres, dirt and grease when installing new
clutch. Cause: 1. Installation error/misalignment
(refer to misalignment tips).
2. This problem is common in 4 wheel drive vehicles when an inspection cover or a clutch fork
cover boot has not been replaced when installing a new clutch. 2. Inferior clutch facings.
SOLUTION: 1. Ensure bell housing is thoroughly degreased and clean of dirt and fibres before installing 3. Diaphragm spring load not to
new clutch. specification.
2. Ensure inspection locations and boots are replaced, tightened and well located. Solution: 1. Replace complete clutch and
Note: These problems are common on farm vehicles, vehicles travelling on sand and 4x4 recreational pilot (spigot) bearings.
vehicles. 2. Avoid misalignment on
installation.
PROBLEM: 1. Installation assist clips not removed. PROBLEM: No clutch adjustment (diaphragm over centre/
2. Slipping clutch/excessive free travel. clutch disc side plate fouling).
3. Unable to adjust. SYMPTOM: 1. Diaphragm over centre when bolting clutch
4. Will not transmit power. cover pressure plate assembly to flywheel.
SYMPTOM: Clutch slipping just after installing new clutch. 2. Clutch disc side plate fouls on I.D. of casting.
CAUSE: Clutch cover pressure plate assembly hold down CAUSE: Careless mechanical fitting practices.
clips, to assist ease of installation, have not been SOLUTION: Always mate clutch disc to pressure plate
removed. casting and flywheel. Ensure no fouling
SOLUTION: Remove clips after installation. occurs before installing new clutch.
PROBLEM: Bearing retainer clip not connected to
diaphragm.
PROBLEM: No gear selection/difficult engagement.
Stretched and damaged retractor clip. SYMPTOM: No pressure on clutch pedal - new pull type
(Clip stretched above diaphragm). clutch just installed.
SYMPTOM: After installation of new clutch, unable to CAUSE: Proper installation procedures have not been
select gear. followed. The snap-in mechanism of the release
bearing has not been clipped on firmly.
CAUSE: Over adjustment of clutch that has caused
stretching of retractor clips on clutch cover SOLUTION: When the transmission if installed onto the
pressure plate assembly. mating area of the engine the release bearing is
preliminarily set into position where the release
SOLUTION: 1. Fit new cover assembly fork of the transmission is fitted.
2. Adjust clutch to manufacturer’s After installation of the transmission the release
specifications. lever must be pulled in the direction reverse to
the release firmly. The bearing is then snapped
in. (Also refer manufacturer’s specifications).
PROBLEM: Crashing gears/stretched and damaged retractor

clip. (Clip under diaphragm).
PROBLEM: Difficult to engage/Disengage gear, Noisy clutch.
SYMPTOM: Difficult engagement/disengagement after
Cause: 1. Interference due to release bearing over
installation of new clutch.
stroke.
CAUSE: Clutch cover pressure plate assembly has been
2. An incorrect clutch disc may interfere with
dropped during installation/or during transit
diaphragm, when you depress the clutch
causing damage to retractor clips.
pedal.
SOLUTION: Always check components before fitting and
Solution: 1. Refer to clutch adjustment procedure, and
ensure that the tip of retractor clip is resting on
adjust pedal free play.
top of the diaphragm. This can be checked by a
feeler gauge. 2. Use the correct clutch disc.
(This is the installer’s responsibility).
Interference
PROBLEM: Clutch diaphragm fingers or levers are uneven.

PROBLEM: Worn clutch disc facing fibers and dirt lodged
between diaphragm spring and clutch cover SYMPTOM: Clutch drag and pedal vibration.
housing. CAUSE: 1. The pressure plate cover assembly was torqued
Symptom: Difficult to disengage gear/ Slipping clutch. down incorrectly i.e. not diagonally.
2. The pressure plate cover assembly was torqued
Cause: Bell housing not degreased and cleaned. down with an air wrench.
Careless installation of new clutch.
SOLUTION: 1. Refer to EXEDY/Daikin packaging for correct
Solution: Ensure bell housing is thoroughly degreased sequence to tighten bolts.
and clean of dirt and fibers before installing new 2. Never use air tools to torque down a clutch.
clutch.
*Refer to page 70 for proper tightening specifications..
Worn facing fibers and dirt lodged
PROBLEM: Excessive wear on diaphragm tips and a highly
glazed pressure plate casting.
SYMPTOM: Slipping clutch/shudder/judder.
PROBLEM: Clutch diaphragm fingers or levers are uneven.
CAUSE: 1. Lack of free travel/bearing riding on
diaphragm. Symptom: Clutch drag/Judder/Noisy clutch.
2. Driver resting foot on clutch pedal. Cause: The pressure plate cover assembly was torqued
down incorrectly i.e. not diagonally.
3. Quill shaft worn/bearing stuck on a worn spot
and not returning to original position. Solution: Tighten bolts temporary by hand, then torque
down in correct diagonal sequence one by one.
4. Clutch slave cylinder corroded or worn and
piston not returning to allow free travel.
5. Stretched or sticky cable.
Uneven diaphragm tips
SOLUTION: 1. Adjust free play in clutch to specification.
2. Driver education.
3. Replace quill shaft (gear box main drive nose
cone).
4. Replace clutch slave cylinder and check
pressure build up in clutch master cylinder. PROBLEM: No clamp load on to clutch disc.
5. Replace cable. (Do not re-oil old cable). SYMPTOM: Slipping clutch.
CAUSE: 1. Diaphragm spring load below specifications.”
Due to design of cover type, diaphragm has not
been replaced.
2. Inferior remanufacture/spring load not
checked.
SOLUTION: Replace with only a new EXEDY/Daikin pressure
plate cover assembly.
PROBLEM: Unable to change gear/bent drive straps.
SYMPTOM: No disengagement.
CAUSE: 1. Improper driving practice.
2. Distorted retractor leaf spring caused by
extreme reverse thrust load spring.
3. Sudden down changing of gears i.e. 5th gear
to 2nd gear. PROBLEM: 1. Hold down bolts still in pressure
plate assembly.
4. Wrong clutch cover assembly used due to
2. Unable to adjust.
engine turning direction.
3. Will not transmit power.
5. Constant “dropping” of clutch at extremely
high revs when taking off. SYMPTOM: Clutch slipping just after installing new clutch.
SOLUTION: 1. Driver education. CAUSE: Clutch cover pressure plate assembly hold down
bolts to assist ease of installation not removed.
2. Install correct cover assembly for application.
SOLUTION: Remove hold down bolts.
3. Fit extra straps to suit heavy duty application
1. Do not remove clutch lever
(optional), or use EXEDY/Daikin Sports clutch.
adjustment nuts.
2. Common in Japanese trucks
Malfunctions of Other Clutch Components
PROBLEM: Rattle while idling from clutch area mostly after
PROBLEM: Engine revving when power applied during new clutch is installed. Worn absorber rubber tip.
acceleration/will not transmit power. Evidence of
oil contamination on cover assembly. SYMPTOM: Clutch fork rattle whilst idling.
SYMPTOM: Slipping clutch. CAUSE: 1. Some clutch thrust bearing carriers are held
firmly by an absorber rubber bush that wears.
CAUSE: Clutch cover pressure plate assembly
contaminated with oil. 2. Clutch thrust bearing carrier saddle worn.
SOLUTION: 1. Rectify oil leaks. SOLUTION: 1. Rectify by fitting new absorber rubber bush
to prevent the fork dropping against the bell
2. If re-using a new cover that has been housing window and rattle.
contaminated with oil, de-grease the cover
assembly and lightly lubricate diaphragm pivot 2. Always check for wear on clutch thrust bearing
rings before re-installing with light base oil. carrier saddle. Replace is necessary.
PROBLEM: Excessively scored clutch cover pressure plate PROBLEM: Power not transmitted in first gear when
assembly. taking off/or slipping for a few seconds at take
off. Damaged or excessively worn dual mass
SYMPTOM: No disengagement. flywheel.
CAUSE: Fouling of clutch disc side plate hub on casting SYMPTOM: Slipping clutch for vehicle with dual mass
of pressure plate assembly, due to clutch disc flywheel.
and clutch cover pressure plate assembly being
of two different and conflicting brands. CAUSE: Worn or broken arc springs in dual mass flywheel.
SOLUTION: Always use EXEDY/Daikin matching clutch SOLUTION: 1. Replace dual mass flywheel.
disc and clutch cover pressure plate assembly 2. Always check dual mass flywheel thoroughly
to ensure Original Equipment quality and for excessive rotation travel.
compatibility.
PROBLEM: Warped clutch cover pressure plate assembly

casting. PROBLEM: Clutch pedal stuck to the floor.
SYMPTOM: Clutch drag/no disengagement. SYMPTOM: No disengagement.
CAUSE: Only clutch disc was replaced which caused a CAUSE: broken ear on release bearing.
vacuum not allowing the clutch disc to separate
from the clutch cover pressure plate assembly SOLUTION: 1. Always follow manufactures installation
casting, when clutch is in disengaged position. procedure when fitting bearing to fork.
SOLUTION: Always replace clutch disc/clutch cover pressure 2. Inspect bearing before installation for
plate assembly and clutch thrust release bearing damage..
when replacing clutch system.
PROBLEM: High pitched squeal. Excessive worn diaphragm

PROBLEM: Worn fixed gear box quill shaft/gear box nose
spring.
cone slide.
SYMPTOM: Noisy clutch thrust bearing.
SYMPTOM: Notchy clutch pedal when depressing clutch.
CAUSE: Clutch thrust bearing fitted incorrectly e.g. back
CAUSE: Worn quill shaft/gear box nose cone slide not
to front.
replaced.
SOLUTION: Replace with new bearing fitted correctly i.e.
SOLUTION: Renew or re-sleeve gear box quill shaft.
right way round.
PROBLEM: Unable to select gear and unable to stop

rotation of main drive shaft.
SYMPTOM: Clutch brake not operating (large pull type
PROBLEM: High pitched squealing noise. Damaged bearing.
clutch).
SYMPTOM: Noisy clutch thrust bearing in new clutch
CAUSE: 1. Wear on fingers of the clutch release
(installed).
yoke mechanism, which include cross
shaft bushings. CAUSE: Bearing fitted incorrectly.
2. Excessive wear on bearing housing head SOLUTION: Fit new clutch thrust bearing right way round.
fork saddle.
Note: Ensure cover pressure plate assembly
SOLUTION: 1. Replace all worn bushings in relation diaphragm has not been damaged from previous
to release lever mechanism. clutch thrust bearing.
2. Replace bearing head assembly.
3. Readjust to specification.
PROBLEM: Damaged clutch thrust bearing. Diaphragm

PROBLEM: Worn quill shaft. spring excessively worn.
SYMPTOM: 1. Clutch fork rattle. SYMPTOM: Continuous clutch thrust bearing noise.
2. Sticky clutch pedal/pedal graunch. CAUSE: The clutch has not been adjusted correctly since
installation or the clutch has never been adjusted
CAUSE: 1. Clutch thrust bearing carrier not travelling
during any routine service. The clutch thrust
smoothly on quill shaft/gear box nose cone slide.
bearing and the diaphragm of the clutch cover
2. Misalignment. pressure plate assembly have worn indentations
into each other.
SOLUTION: 1. Always replace worn quill shaft/nose
cone gear box slide when installing new clutch. SOLUTION: 1. Fit new clutch kit as it is too late for
adjustment of old clutch.
2. Refer misalignment tips.
2. Always check free travel at service.
PROBLEM: Difficult to disengage gear/Slipping clutch.

Symptom: Malfunction of cylinder assembly. PROBLEM: Notchy clutch pedal/Slipping clutch.
Cause: In case of CSC, Concentrated Slave Cylinder, Cause: Abnormal wear on front cover, notchy wear.
internal piston not traveling smoothly causes
system failure, and it may result in following Clutch release bearing carrier not travelling
symptom; smoothly on quill shaft/gear box nose cone slide.
Difficult to disengage gear: Solution: Apply appropriate grease. Renew worn out parts
1. Fixing or sticky movement causes short stroke or scratched parts.
and results in difficult to disengage.
2. Leaking oil causes short stroke and results in Notchy wear on front cover
difficult to disengage:
Slipping clutch:
1. Oil on a friction facing due to leakage from
cylinder assembly causes slipping clutch.
2. In case of malfunction in regard to piston
return, it causes continuous semi-disengagement PROBLEM: Difficult to engage gears. Noise when clutch is
and results in slipping clutch as well as facing engaged.
abnormal wear and burst by burnout.
SYMPTOM: Damaged pilot busing.
Malfunction of cylinder assembly Solution: Always replace with new cylinder assembly.
Cause: Improper installation practices. Forcing the input
Install cylinder assembly after ensuring smooth shaft/transmission on crank bushing engine
movement. block.
Solution: Align the transmission to the crank/engine block
during installation. Never force transmission to
engine.
Do not use bell housing bolts to force the
transmission on to the engine block.
Proper installation practices.
PROBLEM: Clutch slipping, premature wear.

Cause: Slipping:
Not enough friction area causes less torque
transmittance and results in slipping under heavy PROBLEM: Difficult to disengage gear/Noisy clutch.
load due to reuse of worn flywheel.
Cause: Reuse of pilot bearing.
Premature wear:
Reuse of worn flywheel is same condition as Noise:
worn clutch disc, and it results in premature wear. Reuse of deteriorated pilot bearing may
If you resurface friction surface only, it causes cause abnormal noise from the bearing under
premature wear as well depressing clutch pedal condition.
Solution: 1. Replace with new clutch. Difficult to disengage gear:

Reuse of bearing which is not smooth movement
2. Use flywheel which has the same dimension causes difficult to disengage gear, because
as new, the height « between clutch cover it transmits torque under disengagement
mounting surface and friction surface shown in condition.
figure.
Solution: Always replace with new pilot bearing when you
replace clutch. Deteriorated pilot bearing
Flywheel with deteriorated friction surface
Diagnosing Bearing Noises
Diagnosing Bearing Noises

PROBLEM: Excessive score marks on clutch thrust bearing.
SYMPTOM: Excessive free travel/clutch does not disengage/ 1. Clutch release bearing
noisy - Japanese range of trucks.
A. Depress the clutch pedal
CAUSE: Incorrectly fitted clutch thrust bearing carrier approximately 2”. the bearing
to clutch release fork causing bearing carrier to is now in contact with the
spin off the fork tips and bearing carrier saddle. diaphragm. Should the bearing
This problem could also be caused if the tension rumble or squeal then the
on the release bearing carrier wire clip in not clutch release bearing is most
sufficient.
likely at fault (providing it has
SOLUTION: 1. All care should be taken when replacing been pressed onto the carrier
bearing carrier on the clutch fork. Also ensure the the right way around.)
retaining spring clip has sufficient tension.
2. Always work clutch thrust bearing carrier both 2. Pilot Bearing or Bush.
forward and backward to ensure that the fork is A. With engine running depress
retained firmly on the carrier saddle. the clutch fully.
B. Select first gear.
C. Release the clutch.
If the squeal is heard at the
point of the clutch taking up,
then the pilot bearing is faulty.
PROBLEM: Broken saddle clip. In the event it is a bronze bush
it will indicate lack of lubrication
SYMPTOM: Noisy rattle and difficult to engage gear.
on the I.D. of the bush. If the
CAUSE: Careless installation as spring retaining clip not bush has been lubricated
assembled to fork during installation, or tension on the I.D. there is a greater
on wire retaining clip not correct. possibility that the O.D. of the
SOLUTION: 1. Check tension on wire retaining clip. bush is under sized and worn.
The noise is then caused by
2. Always check bearing on clutch release fork the bush spinning in the end
after installing bearing on it. Move the fork in
of the crank. If new pilot bush
both directions to ensure bearing is secure
before refitting gear box. has not been pressed in evenly
this could also result in the bush
spinning which would cause
a grumbling or squealing
noise. Pilot bush noises are
more apparent when engine
and transmission are cold.
(i.e. In the morning).
PROBLEM: Worn clutch thrust bearing carrier. 3. Front gear box

SYMPTOM: Pulsating pedal with engine running.
bearing
A. Drive the vehicle at
CAUSE: Faulty installation as the clutch thrust bearing approximately 30 kilometers
carrier is worn on the saddle where the fork per hour in gear. If a
pivots. This also reduces the tension on the noticeable grumble noise is
wear clip retainer. In this case, due to the lack apparent, depress the clutch
of tension the fork has become dislodged and
pedal. This will, in turn, stop
scored the back of the bearing.
the main drive and bearing
SOLUTION: Always replace worn clutch thrust bearing from spinning. If noise ceases
carriers and worn forks. it is probable that the front
gear box bearing is faulty
(as there is no load on the
bearing).
Malfunctions of Sports/Performance Clutches
PROBLEM: Difficulty changing gears.

CAUSE: Intermediate plate not in the correct location on
PROBLEM: Noise, Difficultly engaging gears. the flywheel.
CAUSE: Broken drive hub on clutch disc. Damaged stop SOLUTION: Always line up the blue marks on all the
pin from high RPM clutch “dumping” of “side components during installation.
skipping” from a stop.
Tech Tip: A center punch can be used to leave an
SOLUTION: Driver education, change driving style. indentation on each component as the paint can
be affected by chemicals
PROBLEM: Gearbox noise, difficulty changing gears.

CAUSE: Damaged spline hub and disc due to one or
more of the following:
1. Inadequate lubrication on input shaft
2. Burrs on input shaft of transmission not
PROBLEM: Clutch slippage. allowing hub to slide freely.
CAUSE: Over greasing the input shaft. 3. Too much pressure plate left from improperly
SOLUTION: Use a thin coating of grease, uniform and evenly adjusted pedal stop or hydraulic assembly.
on input shaft. 4. Bad input shaft bearing, pilot bearing or pilot
Tech Tip: Slide clutch disc on to input shaft to evenly bushing causing hub to wobble against discs.
distribute grease on spline. Wipe away all excess SOLUTION: 1. Use proper lubrication on input shaft.
grease from end of spline and disc. Be careful not
to touch facing of disc with grease. 2. Inspect input shaft on transmission for burrs or
damage.
3. Properly adjust pedal stop and/or hydraulic
assembly.
4. Measure input shaft in play, inspect pilot
bearing/bushing.
PROBLEM: Difficultly changing gears.

CAUSE: Mis-shift at high RPM or aggressive down
shifting at high RPM.
SOLUTION: Driver education, Change driving style, use lug
type multi plate clutch.
PROBLEM: Clutch slippage “slipping”.

CAUSE: Loose cover assembly bolts from improper bolt
tightening torque procedure.
SOLUTION: Use manufacture bolt torque specs. Tighten
evenly. Use thread locker to ensure bolts do not
loosen.
Refer to page 70 for proper tightening
specifications.
PROBLEM: Chipped facing.

CAUSE: Improper break in of clutch assembly.
SOLUTION: Follow manufactures break in procedures.
PROBLEM: Difficulty changing gears.

PROBLEM: Difficultly changing gears, no release. CAUSE: Spline damage on the bottom disc(s) from not
CAUSE: Debris built up in pivot ring area between cover being aligned properly.
and diaphragm spring. SOLUTION: Use the proper alignment tool for vehicle
SOLUTION: Disassemble cover assembly and clean application.
thoroughly. Tech Tip: Twist the alignment tool to align the bottom
discs while finger tightening the cover bolts.
1. What vehicle does the customer have? You will want to know the following. d. EXEDY Stage 3, 4 Carbon** disc with sprung hub center section is a great choice for the
Choosing the Correct EXEDY Sport/Performance Clutch

Choosing the Correct EXEDY Sport/Performance Clutch
a. Manufactures exact model and model year. “dedicated race car” who wants a very smooth engaging clutch with little to no driveline
vibrations. The carbon disc is a very lightweight resulting in extremely quick shifts.
b. Engine size and engine code.
e. EXEDY Stage 3, 4, 5 Carbon** disc with solid hub center section is a great choice for the
c. If they have altered the vehicle by doing a engine swap or a transmission swap.
“dedicated race car” who wants a very smooth engaging clutch that is very lightweight for
d. If they have updated or back dated any of the engine and/or transmission components. extremely quick shifts.
e. Good to know information if at all possible **Carbon clutches are not recommended for street use due to the inconsistent friction coefficient
1. Input shaft size (measure the outer most diameter of the input shaft spline) from hot to cold. Carbon clutches require a warm up procedure before being driven aggressively.
2. Disc size outer diameter Due to this nature we only recommend carbon clutches for race only applications or to customers
who completely understand the characteristics of a carbon clutch. A very big misconception of a
3. Vehicle chassis code
carbon clutch is that the vehicle is warm so isn’t the clutch? These units work excellent on dedicated
2. How much power does the vehicle make? Always ask the customer for torque race cars due to the driver being able to do the warm up procedure prior to the start of the race and
output at the wheels. Horsepower is a very subjective figure so try to avoid every time driver upshifts or downshifts at higher RPM he is continuing to add heat to the clutch disc.
In a street car you often stop at lights, drive in a specific gear, or shift at a lower RPM not allowing
using this figure.
adequate heat to be given to the clutch disc. Without heat in a carbon clutch the friction coefficient is
a. If your customer is unsure about their torque output you will need to find out what
significantly lower than when heated. It is at these points in a street car that the customer may decide
modifications they have done to the vehicle. Knowing the vehicles base line torque output
to put the pedal to the metal causing the clutch to slip and wear out prematurely due to inadequate
and basic research on how much additional power each component has added you can
heat being in the clutch disc.
figure out the estimated torque output.
b. Since your estimated torque output will generally be a flywheel torque figure you will want 5. Lightweight flywheels for the Stage 1, 2 clutch kits are great options to;
to remove 20% from your estimated torque output to come up with your estimated wheel a. Improve throttle response.
torque figure. b. Allow the engine to rev more quickly.
c. If the customer has not done any modifications there is no need for a sports/ racing clutch. c. Allow the clutch to operate cooler.
Sport/racing clutches are intended to handle a increase in torque above and beyond the
capacity of the OEM clutch. Sports/racing clutches are not going to last longer than that of a d. Burst tested and SFI approved. Rated to 10,000+RPM.
OEM clutch even if the vehicle is stock as that is not the purpose of a sports/racing clutch. e. Remove the OEM dual mass flywheels.
All EXEDY lightweight flywheels are made from a one piece forged chromoly steel which utilize a
3. What type of driving is the customer going to be doing?
nitrate hardening process, unique cooling ducts and distribute the weight evenly to allow for better
a. Street driving
drivability on the street.
b. Street / Strip / Weekend racer
c. Dedicated race car 6. How to set-up and what to expect from an EXEDY sport/racing product.
a. Break in period should be that of 500 miles of city type driving, double the break in period for
4. Now that we know the vehicle model, torque output and type of driving the highway driving. No aggressive driving. No hole shots or drag launches. Gear changes should
vehicle is being used for we can give the customer a good recommendation be made at 4,000 RPM or less. No speed shifting.
on clutch type (stage). b. Installing a sports/racing clutch to suit various vehicles can transfer harmonic noises from
a. EXEDY Stage 1 clutch is great for the customer looking for a very smooth engaging clutch the engine to the gearbox. This is also called gearbox rattle. This can occur at idle and during
that is going to drive similar to the OEM unit but capable to handle moderate levels of acceleration/deceleration.
modifications. This is a great option for the “street driver”.
c. Clutch engagement can be compromised by installing a sports/racing clutch. This is due
b. EXEDY Stage 2, 3, 4 Cerametallic disc with sprung hub center section is a great choice for the to the heavier torsional dampening springs and/or the solid hub center on the clutch disc.
”street / strip / weekend racer” with applications to handle moderate to aggressive levels Another factor is due to reduction in cushion plate thickness within an organic clutch disc
of modifications. These units offer a very consistent operation whether being raced or daily and/or no cushion plate on the cerametallic and carbon clutch discs. The best way to remedy
driven. The sprung hub center offers ease of engagement and absorbs many of the driveline this situation is a take off at a slightly higher RPM and/or let the clutch out a bit quicker.
vibrations at idle and during acceleration/deceleration.
d. Since most of the stage 4 and 5 multi-plate clutch kits have a free floating pressure plate and
c. EXEDY Stage 4, 5 Cerametallic disc with solid hub center section is a great choice for the intermediate plate there will be a metal on metal noise when the clutch is depressed. This is
“dedicated race car” or very highly modified ”street / strip / weekend racer” who doesn’t not common on most multi-plate clutches and is acceptable within the racing industry.
mind sacrificing drivability for performance. This type of clutch will offer a very consistent
operation however chatter and driveline vibrations will be experienced due to the solid hub
center section.
Flywheels Stage 2 — Cerametallic Friction Disc
Function of Various Sports/Performance Products

EXEDY cerametallic clutches are designed to handle the abuse of high power modified engines.
Lightweight One Piece Chromoly Our cerametallic friction material can handle much more abuse than stock type disc assemblies
EXEDY flywheels combine low weight, low inertia and without slipping and fading.
high thermal capacity. They are designed for lightly tuned
racing cars for drag racing, autocross and rally events, as All EXEDY Stage 2 cerametallic clutch discs have sprung center dampers to reduce the impact and
well as street usage. They are made from solid one-piece shock loads transmitted through the drivetrain. We offer two types of cerametallic discs, “thick”
billet chromoly steel or chromoly steel forgings. They are and “thin.”
specifically designed to reduce weight and inertia for better
engine response. Most incorporate special design features to
enhance the airflow which improves the cooling of the clutch.
The ring gear teeth are integrated onto the flywheel unlike an Thick Disc
aluminum flywheel where the ring gear is pressed onto the flywheel The “thick” discs have better heat
and has the possibility of separating from the flywheel due to the different capacity and therefore better durability
expansion coefficients of aluminum versus steel. EXEDY steel billet and forged steel flywheels have in demanding applications. Even with
passed engineering tests to 15,000-18,000 rpm. They are guaranteed not to fail to the said rpm, and the “thick” disc, our three and four puck
are all SFI approved. designs typically have less inertia than a
stock disc and work well for street, rally and
track use.
Stage 1 — Organic Friction Disc

Ultra Fiber Disc
This advanced facing material provides the high heat
resistance essential for motorsports. It was developed
by reviewing both the copper wire ratio and the
composition of the high strength fiber. The
Ultra Fiber Disc maintains the superior half-
engagement feeling specific to the Organic
material. With improved high heat resistance,
it provides the functionality essential for street Thin Disc
performance and mild racing applications. The “thin” discs offer greatly reduced
inertia to improve shift effort, allow
Organic Disc for quicker shifting, and improve
synchro durability. These discs are
Newly developed asbestos free friction facing
approximately 1/2 the thickness of a
is used, which has high heat resistance and high
stock disc and are recommended for
burst strength characteristics. No steel back is
circuit track use only.
required which can cause high RPM “lock-out” and/
or synchro damage. Superior in shift operations and
half-engagement feel, this clutch disc is recommended for
any sports/performance use.
Clutch Cover
These clutch covers are designed to achieve a clamping load that is approximately 40% higher than
the genuine part allowing a higher torque transmitting capacity. Ductile material is used for all
pressure plates and, high burst strength can be achieved in all temperature ranges.
Stage 3 — Hyper Single Clutch Patented One Touch Snap in Function

The problem of detachment difficulties is solved by the use of EXEDY original one-touch snap in
The Hyper Single Clutch is engineered to optimize the performance of bearing design. Detachment can easily be accomplished with the use of a screwdriver, alternatively,
cars that are moderately modified, but do not require the clutch the bearing can be snapped back into place while activating the release fork.
capacity of a multi-plate clutch. Similar to our multi-plate
clutches, it has a purple anodized, forged aluminum cover.
The aluminum cover is stiffer than a stamped cover and
What is Inertia?
therefore allows a higher lever ratio to maintain the Inertia is the tendency of the clutch and flywheel to maintain rotation even when not connected to
pedal efforts at a reasonable level. There is no clamp the engine torque. This affects the responsiveness of the engine and also the feel of low rpm torque
load deflection as found in a pressed metal type cover. and start up drivability.
All Hyper Single clutches come with a chromoly steel In the case of the clutch disc, lower inertia is always better to improve shift efforts and reduce the
flywheel, 6-puck cerametallic facing and a spring center wear on the transmission synchro’s.
damper disc assembly. The disc is generally smaller
and thinner than the OEM disc making for lower inertia
and therefore quicker, easier shifting and less wear and
tear on the transmission synchro’s. The higher clamp load Stage 4 & 5 — Hyper Multi-Plate Clutch
and cerametallic friction facings give approximately twice
the holding torque of the OEM clutch and generally higher than other single plate clutches. An Twin and Triple Plate
additional feature of the pressure plate is a series of turbine-like, air flow enhancing vanes that keep For high-powered applications, EXEDY offers twin and triple
the clutch cooler under extreme operating conditions to improve wear life. Multi-Plate Clutches. These are designed for high power
• High friction coefficient, low wear, and a special heat resistant material (T5001) has been street action as well as drag, road and rally racing.
developed enabling clutch size to be reduced and increased durability to be achieved. The twin plate clutches are rated for approximately 500
• Durability is improved with the use of a stronger, smaller damper disc, specifically ft.lbs. TQ @ FW. The triple plate clutches are rated for up to
redesigned for the Hyper Single Clutch. and over 800 ft.lbs. TQ @ FW. Twins come with both spring
• A lower level of inertia is achieved over the genuine fitment clutch which improves shift damper discs or solid discs depending on application. Triples
response for faster gear changes particularly for racing applications. are all solid discs and not recommended for street use.
All of our multi-plate clutches come with a lightweight, chromoly
Pull Type Clutch steel flywheel and the famous purple anodized forged aluminum clutch
The pull type clutch accommodates higher torque, in conjunction with lighter pedal efforts to cover. Depending on the application, we have both strap drive and lug drive models. All have T5001
produce a superior clutch operation, when adapted to most high-powered vehicles. An EXEDY cerametallic friction materials for extreme heat resistance.
Original design.
SD Type
Advantages This model has been developed for high powered street cars and race cars with up to approximately
• Unlike the push type 600TQ @ FW. They feature ventilated, thick intermediate plates for improved life and spring damper
cover, when a pull discs to protect your transmission and drive line.
type cover flexes, it will
flex in the direction of
disengagement, assisting
SR Type
in positive pedal feel. This model has twin or triple plates developed to be lightweight for quick response. The Triple plate
model is available for over 800TQ @ FW and the twin plate model is rated to approximately 600TQ @
• A longer lever ratio FW. The combination of ultra lightweight solid discs and a lightweight chromoly flywheel gives the
achieves a direct decrease driver a lightened pedal effort and quick response. This can improve your times when running at the
in pedal effort. drag strip or road course. They feature ventilated, thick intermediate plates for improved life
HR Type
This model has three plates and is developed specifically for high power applications such as over
800TQ @ FW for drag racing. It handles high torque loads and shifts smooth, and because of the
lightweight clutch discs, you can reduce your shift times.
Patented Center Plate Self Leveling Function Hyper Carbon Series

The amount of center plate travel during release is always maintained in a neutral position by the
reaction force of the lifting plate attached to both sides of the center plate. The flagship model of EXEDY clutches, the Carbon Steel Multi-Plate
Clutch. These Clutches are lightweight, durable and resilient to high
heat, contributing to an improvement in track times.
Warm Up Procedure
Due to the inherent properties of the carbon
material, we must specify the proper way to
bring the discs up to operating temperature.
This Process will heat the discs so they will hold
the specified torque rating. The correct method
• Improved disengagement (accelerated separation from friction surface). is three, five second “slips” of the clutch within
• Improved disc life by eliminating unbalanced wear at the T/M and F/W side. 30 seconds at low RPM.
• Prevents and lowers mechanical noise.
High Heat Resistance
Carbon materials are baked at more than 3600 degrees Fahrenheit, which allows the carbon
Working Theory material to dissipate heat far better than conventional metallic material. Heat expansion rate is
Due to high temperatures generated by the clutch Patented Clutch 1/20th of iron therefore eliminating a change in clutch feel that may happen due to distortion
caused by expansion during driving. Carbon material not only has a high heat resistance but also a
system during operation, the pressure plate tends to Cushioning Function “non-stick” characteristic that eliminates disengagement problems.
absorb a large portion of that heat, accelerating the
wear of the pressure plate side disc. The Lifting plate The “cushion” function is a new
innovation unique to EXEDY. The
location remains steady between the location area
on the pressure plate shown as (A) and F/W location half engaged “zone” is expanded Light Weight & Low Inertia
as a result of a decrease in rigidity
area shown as (B) on the chart above. Accordingly,
of the pivot ring. Ideal pedal effort Light in Weight
the wear of the pressure plate side disc is accelerated,
resulting in the F/W side disc automatically being is achieved as a result of a longer The heaviest components of the clutch system are
engaged earlier than the pressure plate side, which in lever ratio of the diaphragm the clutch cover, intermediate plates and flywheel.
turn increases the F/W side disc’s work and wear rate. spring coupled with the cushion Semi-Carbon clutches incorporate an improved cover
Therefore, due to an increase in workload during half reaction force. configuration and lightened flywheel also contributing
engaged operations, wear on the F/W side disc will be to a reduction in vehicle rotating weight.
accelerated causing a reduction in the overall friction
material thickness, resulting in the F/W disc registering
a similar thickness friction material to that on the
pressure plate side.
Low Inertia Design
Engine modifications (cam, timing, turbo
modifications etc.) cause engine pulsation and The weight of a carbon clutch disc is one third that of a
vibrations. These vibrations can cause clutch rattle metallic disc. Utilizing a high friction coefficient Hyper
when the clutch pedal is depressed by movement on Carbon disc which allows for quicker shift response. Low
the intermediate separator plate, in some applications. inertia discs allow the transmission to synchronize in a
These noises will in no way affect the performance shorter space of time eliminating time loss during shift
of the EXEDY Multi-Plate Clutch. This rattle is well changing while also reducing the applied load to the
accepted in the performance industry where engine synchronizer.
modifications have been carried out.
Easy to Handle Carbon-D Single

By controlling the carbon fibers • Introduction of a
and baking temperature, the cross 0.49 0.50 damper to absorb and
0.47 0.48 0.48
layer type carbon material, which dissipate noise and
is the most appropriate for high vibration
revolution strength and high torque 0.31 • High clamp load, lower
transmission, is applied to tuning car pedal effort and ideal
clutches. Semi-carbon clutches offer clutch engagement is
lightweight, high heat resistance and obtained with the use
a stable friction coefficient. EXEDY of the re-engineered
Carbon clutches are tuned so that diaphragm spring
at a lower temperature, engagement feeling is improved and conversely at high temperatures, • Quiet Strap Drive design to
engagement is ideal for spirited driving. minimize mechanical noise
• Patent Pending Disc System
Long Life
Semi-Carbon clutches allow double the life when
compared to conventional metallic type material, Carbon-D Twin
which equates to an improved cost performance • Introduction of a damper to absorb and dissipate noise and vibration
thanks to longer overhaul cycles. Full carbon • With a reduction in pedal effort and an increase in disc size to 225mm, the Carbon-D Twin
clutches have more wear than metallic however, clutch is ideally suited to high performance street vehicles
when used with over-sized pressure plates, the life • By optimizing the weight and inertia of the Carbon-D Clutch System, drivability is improved
is identical to metallic. at low speeds
Gear Noise and Fluctuations in Engine Rotation (rpm)

Even engines that seem to run very smoothly always have some amount of fluctuation in engine
rotation. These fluctuations, when transferred from the engine to the transmission, cause gear
Hyper Carbon Series-D teeth carrying no torque to strike mating teeth, resulting in noise (“tooth hammer”). The noise is
louder in the interior as well as outside the vehicle because the clutch housing acts as a speaker and
Introducing the Next Generation of clutch systems by EXEDY – Carbon-D, the magnifies the noise. Although the noise level and noise-generating speed depend on the type and
revolutionary Carbon Clutch System. model of car, such noise is more frequent in a 6-speed vehicle than in a 5-speed vehicle.
Carbon-D was developed to achieve the ultimate goal of comfort
and drivability by absorbing noise and vibration emitted from Vibration-Absorbing Damper
drivetrain components such as the differential,
The conventional damper used in most sports clutches is designed to protect the transmission from
transmission and engine. The Carbon-D system is
shock torque caused by abrupt clutch engagement, so it does little to absorb vibration. Efficient
designed to protect the drivetrain by absorbing
absorption of fluctuations in engine speed requires a very flexible spring and proper setting of
and dissipating “shock torque” by utilizing EXEDY
the hysteresis torque. The flexibility of the spring, however, is likely to run counter to the damper
Patented Technology. Superior engineering
capacity. For this reason, Carbon-D is equipped with a new dual stage damper, a low-load stage
enables the Carbon-D clutch system to posses
and rapid-acceleration stage, both of which are perfectly tuned for each car type. This tuning
an ideal clutch engagement position, increased
technology is available only from EXEDY, the specialist in high performance clutch systems.
clamp loads and lower pedal effort, while the
unique Carbon Fiber friction material allows
comfortable half-engaged clutch operation and
responsive gear changes.
Features of EXEDY Unity Type Dampener
How to Identify Your Clutch
How to Identify Your Clutch
1. Pressure Plate (Clutch Cover)
More Floating Space
Bolt Hole Diameter
PCD
Dowel Hole Diameter
Alternating Points of Friction and Wear
(Pitch Circle Diameter)
A
B
Increased Durability and Superior Performance

C
Part Numer on this Area
A: Pressure Plate Outer Diameter

B: Pressure Plate Inner Diameter
C: 6 digit number on spring surface (Flywheel side)
2. Clutch Disc
A. Outer Diameter
B. Inner Diameter
C. Number of Spline Teeth
D. Spline Outer Diameter
The Points of contact change, While the disc is not in
Spline Enlarge
Causing premature wear operation, the spring can
on both the spring and the now move.* Therefore, when
D window. the disc starts moving area
A
B
View contacting the again, the

spring’s the window will be
different.
C
Parts number on this area

*Because this same movement does not occur during operation,
there is no spring rattle.
Driveline Misalignment in General/Tips
Pull-Type Clutch Design Technology

Driveline Misalignment
STUDY BEFORE ASSEMBLY STUDY BEFORE INSTALLATION
INSTALLATION AND SNAP-IN

PROCESS
PATENTS PENDING
One for Pull Clutch Install bearing on to clutch fork, install transmission
Four for Release Bearing Mechanism (G/Box) then the release fork must be pulled in the
direction reverse to the release firmly. The bearing
is then snapped in.
1. Warped alloy bell housing

DISASSEMBLY
2. Tubular dowel pin guides crushed during fitting of bell housing to mating dowel
pin hole and/or missing dowel pins.
3. Worn gear box quill/gear box main drive nose cone bearing slide: causing bearing
to come in contact with the diaphragm of cover assembly off centre line whilst
actuating clutch.
4. Dirt-chips-wiring harness clips-hydraulic pipe clamp clips – thick grease build up

interfering between the mating surface of the gear box bell housing and motor.
5. Worn Spigot bushes and pilot bearings along with front gear box main bearings to Fig A
be checked for wear.
SNAP - OUT
6. Exchange engines and gear boxes have missing dowel pins. Ensure you remove PROCESS
pins from your product when you send your core for remanufacture and refit when
installing the new clutch.
Move bellhousing back approximately 30 to 40mm, insert screwdriver and
twist as in figure A. Bearing will then snap out from clip mechanism.
Flywheels and pressure plates need to be torqued
Hydraulic Clutch Pedal Adjustment

Torque Specifications for Flywheel & Pressure Plate
down to proper specifications Measure the clutch pedal height.

Standard value (A): 202.1 - 206.1 mm
The reason why these components need to be (7.96 - 8.11 inch)
torqued down to a specific value is to ensure
CAUTION: Do not push in the master
that the components do not loosen up and
function improperly. The clutch and flywheel cylinder push rod at this time,
spin to thousands of RPM’s and have varied otherwise the clutch will not operate
harmonics sent though them by the engine and properly.
drivetrain.
When one side has a greater torque value
combined with centrifugal force and harmonic
vibrations it allows the opposing side with a
lesser torque value to loosen up. Improper
torque is the number one reason
for a given rotating component Measure the clutch pedal clevis pin
to become loose whether it is a play. Standard value (B): 1 - 3 mm
wheel and tire or a flywheel. For
(0.04 - 0.12 inch)
these reasons it is imperative to
torque to proper specifications. CAUTION: Do not push in the master
When tightening flywheel or pressure plate
cylinder push rod at this time, otherwise
bolts you should tighten each bolt a little bit at a the clutch will not operate properly.
time using a star pattern to tighten. This ensures
that each bolt receives an equal torque value.
When tightening bolts that require a specific
torque value NEVER used power tools such
as impact guns or air tools. When tightening
bolts use a calibrated torque wrench to ensure After completing the adjustments, confirm that the clutch pedal free play (measured at
the proper torque is being applied evenly to
the face of the pedal pad) and the distance between the clutch pedal (the face of the
the specific bolts. ALWAYS refer to the vehicles
factory service manual for proper torque pedal pad) and the clutch pedal stopper when the clutch is disengaged are within the
specifications for a given bolt or component. standard value ranges. Standard value (C): 4 - 13 mm (0.16 - 0.51 inch) Standard value
(D): 114.3 mm (4.5 inches) or more
The use of thread locker or Loctite on each
flywheel bolt and pressure plate bolt gives
added insurance to avoid bolts backing
out resulting in damage to the vehicle and
its components. Damage to the crank and
transmission may occur when bolts back out
due to balance being thrown off and or contact
damage of components that have loosened up.
ATTENTION
Knockoffs are Imported into the US and
Beware of Imitations/Inferior Products

Please Read Before Installation
are used in Substandard Clutch Kits
Please read before installation

HYPER CLUTCH
TWIN CLUTCH
TRIPLE PLATE CLUTCH
CARBON CLUTCH SYSTEMS
PLEASE ADVISE DRIVER OF VEHICLE: • Clutch Drag = poor disengagement i.e., commonly known as Gear Box
Grounch/Gear Crash.
Installing a sports/performance clutch to suit various vehicles, • Malfunction of hydraulic actuation system, due to incorrect set finger height.
can transfer harmonic transmitted noises from the engine • Vibration or clicking noise in clutch fork, also due to incorrect set finger
to the gearbox. This may also cause gearbox rattle. These height.
transmitted noises will in no way effect the performance of the • Premature ware of clutch disc, due to PP (pressure plate) tilt lift.
clutch or vehicle and is accepted in the performance industry • Damage to clutch disc splines, due to uneven landing of the PP casting on the
where engine/clutch modifications have been carried out. clutch friction facings.
• All of the above will lead to premature total clutch failure and will snap-out
the snap-in bearing.
Reference cause, replacement of an EXEDY Silent Design long travel clutch disc
to a high torque center EXEDY sports/performance clutch disc is generally the
known cause of this transmitted noise.
For more information on Imitations/Inferior Products,
please visit our website www.exedyusa.com
Notes
Metric & Imperial Measurement Conversion Table
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7/8 7/8
1/4 1/4 _______________________________________________________________________________________________
1/2 1/2
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3/4 3/4
1/8 _______________________________________________________________________________________________
1/4 1/4
_______________________________________________________________________________________________
1/2 1/2
3/4 3/4 _______________________________________________________________________________________________
7/8 7/8 _______________________________________________________________________________________________
1/4 1/4 _______________________________________________________________________________________________

1/4 1/4 _______________________________________________________________________________________________
1/2 1/2
5/8 5/8 _______________________________________________________________________________________________
5/8 5/8 _______________________________________________________________________________________________
7/8 7/8
7/8 7/8 _______________________________________________________________________________________________
_______________________________________________________________________________________________
_______________________________________________________________________________________________
1/8 1/8
1/4 1/4 _______________________________________________________________________________________________
1/4 1/4
_______________________________________________________________________________________________
1/2 1/2
1/2 1/2 _______________________________________________________________________________________________
1/2 5/8
_______________________________________________________________________________________________
5/8 7/8
7/8 _______________________________________________________________________________________________
1/4 _______________________________________________________________________________________________
1/2
1/4 5/8 _______________________________________________________________________________________________
1/2 7/8 _______________________________________________________________________________________________
5/8
7/8 1/2 _______________________________________________________________________________________________
5/8 _______________________________________________________________________________________________
1/2 3/4
5/8
_______________________________________________________________________________________________
3/4 3/4 _______________________________________________________________________________________________
3/4
_______________________________________________________________________________________________
3/4 _______________________________________________________________________________________________
3/4
_______________________________________________________________________________________________
3/4
1/8 1/8 _______________________________________________________________________________________________
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Copyright © 2013 by EXEDY Globalparts Corporation
All Rights Reserved. Content may not be reproduced, published or transferred in any form or
by any means except with the prior written permission of EXEDY Globalparts Corporation.
Printed in U.S.A.
Prepared by Evan Cline, Steve Kaminski and Jennifer Sinclair
EGP - 10/13/2013

Fault Finding Guide Web

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1973 Established DYNAX Corporation in Hokkaido. RU

8601 Haggerty Road South, No.4 Longjing Road, North New

2001 Strategic Alliance with Aisin Seiki Co., Ltd.

Unit 2, Rokeby Court, Manor Park, 700/316 Moo 6, Bangna-Trad Road,

EXEDY Australia Pty. Ltd.

21 Fiveways Boulevard, Jl. Permata V Lot EE 3 Kawasan

Established July 1950

151 Wairau Road Glenfield Plot No.L-4, M.I.D.C. Industrial Area,

As of 3/31/2011 Non-Consolidated 3,615 EXEDY Middle East Fzco

EXEDY Guangzhou Co., Ltd.

No.406 E-Area, Longfu Car PT 16748, Jalan Permata 1/5,

EXEDY Latin America, S.A.

P.H. World Trade Center, Piso 3, Oficina 303

Function of a Manual Clutch

Do not use Exedy OEM

Function of a Manual Clutch

Function of a Twin Plate Manual Clutch

FLYWHEEL SIDE CLUTCH DISC

Check Before Replacing

Installing your new EXEDY/Daikin Clutch Page 18 Causes

No acceleration •Burning smell 9E

Check Before Replacing

Check before replacing the clutch Check after removing transmission

5A specified, low viscosity oil.

5B • Abnormal idling RPM. Heavy vibration and rumblings.

5F • Malfunction of release bearing or pilot bearing.

5G • Interfering noise by jolting of driveline under driving torque.

5I Exchange specified transmission oil.

Check Before Replacing

Check before replacing the clutch Check after removing transmission

• Is the clutch pedal height or free play appropriate?

7I • Is the clutch pedal height and free play adequate?

Check Before Replacing

Check before replacing the clutch Check after removing transmission

9A • Is there any problem with installation of clutch cable?

• Check the failure and direction on a release bearing.

9C • Failure of transmission, if it is a particular gear. (except reverse gear)

9F • Does a clutch pedal operate smoothly?

Malfunctions of Clutch Discs

PROBLEM: Oily facings.

PROBLEM: Broken facings.

Malfunctions of Clutch Discs

PROBLEM: 1. Crashing noise in gear box, non release.

Malfunctions of Clutch Discs

PROBLEM: No drive, power not transmitted because of

PROBLEM: Premature wear cerametallic button type clutch

Malfunctions of Clutch Discs

PROBLEM: Noisy and cannot transfer power/splines

Malfunctions of Clutch Discs

Problem: Wrong type of lubrication on input shaft spline.

Malfunctions of Clutch Pressure Plate Cover Assemblies

Malfunctions of Clutch Pressure Plate Cover Assemblies

PROBLEM: Mirror finish on pressure plate friction surface.

PROBLEM: Burst pressure plate casting.

Malfunctions of Clutch Pressure Plate Cover Assemblies

PROBLEM: Crashing gears/stretched and damaged retractor

PROBLEM: Clutch diaphragm fingers or levers are uneven.

Worn facing fibers and dirt lodged

PROBLEM: Warped clutch cover pressure plate assembly

5I Exchange specified transmission oil.