Cause
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Action
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DEFINITION: The clutch does not disengage completely to allow smooth shift operations. It may cause gear clashing while the vehicle is not moving, at idle, and shifting out of neutral, or hard shifting in and out of gears while driving the vehicle.
Review the
Symptoms - Clutch
and perform the necessary inspections.
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Pedal blocked from full travel
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1.
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Inspect for obstacles that prevent the pedal from going to the floor.
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2.
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Clear any obstacles from under the pedal area, such as floor mats, damaged floor, or interior panels.
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Too much travel between pedal and clutch master cylinder
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1.
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Inspect the pedal for worn bushings.
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Clutch pedal mounting loose
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1.
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Inspect the clutch pedal mounting bracket for loose or missing fasteners.
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Linkage at pedal worn or damaged
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1.
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Inspect the linkage at the pedal for excessive wear.
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Clutch master cylinder seized or binding
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1.
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Inspect the master cylinder for the piston being able to move freely and full range of travel.
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Air in the clutch hydraulic system
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Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch System Bleeding
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Clutch actuator cylinder seized or binding
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1.
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Inspect the clutch actuator piston for moving freely.
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Clutch master cylinder leaking internally
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1.1.
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Let up halfway on pedal.
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1.2.
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Apply the pedal a few times and hold down for 30 seconds.
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1.3.
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Inspect to ensure there is still the proper pedal reserve, without letting pedal fully up.
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Damaged clutch assembly components
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1.
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Remove the clutch assembly.
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2.
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Inspect the following clutch assembly components for damage:
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Damaged clutch disc hub splines
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Broken or warped pressure plate
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Excessive side loading on the release bearing
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1.
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Inspect the following clutch system components:
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Worn or damaged pilot bearing
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Excessive flywheel runout
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Excessive engine to transmission misalignment
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Clutch actuator cylinder mounting surface out of alignment
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2.
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Repair or replace any faulty components.
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Tight or contaminated clutch disc splines
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1.
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Clean the clutch disc and input shaft splines.
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Grease or oil contamination on the clutch discs facing
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2.
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Repair the grease leak.
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3.
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Clean the clutch disc facing and the other clutch assembly components.
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