Clutch Cover Difficult Engagement/Disengagement

Excessive wear on diaphragm tips and a highly glazed pressure plate casting.

    • Lack of free travel/bearing riding on diaphragm.
    • Driver resting foot on clutch pedal.
    • Quill shaft worn/bearing stuck on a worn spot and not returning to original position.
    • Clutch slave cylinder corroded or worn and piston not returning to allow free travel.
    • Stretched or sticky cable.
    • Adjust free play in clutch to specification.
    • Driver education.
    • Replace quill shaft (gear box main drive nose cone).
    • Replace clutch slave cylinder and check pressure build up in clutch master cylinder.
    • Replace cable. (Do not re-oil old cable).

Clutch diaphragm fingers or levers are uneven.

    • The pressure plate cover assembly was torqued down incorrectly i.e. not diagonally.
    • The pressure plate cover assembly was torqued down with an air wrench.
    • Refer to EXEDY packaging for correct saquence to tighten bolts.
    • Never use air tools to torque down a clutch.

No gear selection/difficult engagement.

  • Over adjustment of clutch that has caused stretching of retractor clips on clutch cover pressure plate assembly.

    • Fit new cover assembly.
    • Adjust clutch to manufacturer's specifications.

Difficult engagement/disengagement after installation of new clutch.

  • Clutch cover pressure plate assembly has been dropped during installation/or during transit causing damage to retractor clips.

  • Always check components before fitting and ensure that the tip of retractor clip is resting on top of the diaphragm. This can be checked by a feeler gauge.
    (This is the installer's responsibility).

Diaphragm fouled on clutch disc. Crashing in gear and unable to obtain clutch adjustment.

    • Flywheel depth or step incorrect.
    • Clutch thrust bearing fallen off quill end/gear box nose cone slide.
    • Clutch disc too thick.
    • Incorrectly adjusted (overthrow of clutch mechanism).
    • Check flywheel depth or step height.
    • Check for wear on release bearing quill shaft/gear box nose cone slide.
    • Check clutch disc thickness.
    • Refer to clutch adjustment procedure or replace cable.

Worn clutch disc facing fibres and dirt lodged between diaphragm spring and clutch cover housing causing loss of clamp load.

    • Bell housing not degreased and cleaned. Careless installation of new clutch.

      The new clutch disc has not worn but the fibres that have become lodged in the new clutch cover are that of the previously worn clutch. It is a requirement due to ventilation designs that the bell housing area be free from old fibres, dirt and grease when installing new clutch.
    • 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.
    • Ensure bell housing is thoroughly degreased and clean of dirt and fibres before installing new clutch.
    • Ensure inspection locations and boots are replaced, tightened and well located.

      Note: These problems are common on farm vehicles, vehicles travelling on sand and 4X4 recreational vehicles.

Unable to change gear/bent drive straps.

    • Improper driving practice.
    • Distorted retractor leaf spring caused by extreme reverse thrust load on spring.
    • Sudden down changing of gears i.e. 5th gear to 2nd gear.
    • Wrong clutch cover assembly used due to engine turning direction.
    • Constant "dropping" of clutch at extremely high revs when taking off.
    • Driver education.
    • Install correct cover assembly for application.
    • Fit extra straps to suit heavy duty application (optional), or use EXEDY Sports clutch.