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CLUTCH FAULT DIAGNOSIS GUIDE
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- 4/25/2010
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LO S S O F D R I V E
CLUTCH
F A U LT
FAU LT DIAGNOSIS
Loss of drive
Facing material broken GUIDE
C AU S E
Friction material damaged prior to or during fitment
Overheating due to slip
Incorrect clutch fitted for the application. Possible driver abuse
AC T I O N
Handle with care
Ensure correct clutch is fitted for the application
Rectify cause of slipping. Advise driver about clutch mechanics
FAU LT
Loss of drive
Driven plate centre broken
C AU S E
Misalignment between engine and gearbox
Faulty fitment of parts
AC T I O N
Ensure correct engine/gearbox alignment
Clutch to be fitted in line with manufactures instructions
Q u i n t o n H a ze l l A u t o m o t i ve
H azel l Way
B e rmuda R oad
Nuneaton
CV10 7QQ
England.
www.thomasbct.com.au The Advantage You Deserve
CLUTCH
F A U LT
DIAGNOSIS
GUIDE
Endurance testing
H OW TO U S E T H I S G U I D E All aspects of clutch performance are analysed by
accelerated wear/fatigue simulation, enabling QH to recreate
the effects of many thousands of road miles.
Problems are categorised by major symptoms 100% all new
The tests used include: -
Every single part of Quinton Hazell’s vast range of clutch
e.g. clutch drag, clutch noise, etc.These are components is manufactured from 100% all new materials. At our
High speed stress reversals of diaphragm springs and driven
plate components.
specialist factory stringent quality control is applied at every stage
identified by photograph with the mode of of manufacture, from the receipt of raw materials to the despatch of Extended, rapid actuation of cover assemblies.
the finished clutch.
failure highlighted and described. Centrifugal burst testing of covers and plates at speeds far in
This is your guarantee that there will be no compromise in the excess of maximum engine r.p.m.
performance or reliability of QH clutches.
Under each section the reason, cause and
Helping solve the problems
Investing in the future
action is clearly detailed. With the clutch fault diagnosis guide, QH Technology can go further
Recent investment of over £3 million in production technology and in helping you to diagnose problems.This brochure will enable you to
test equipment has made the Quinton Hazell clutch factory one of identify the causes of clutch failure associated with possible incorrect
the most advanced. We even manufacture our own diaphragm springs fitting and misuse, as well as recommending corrective action.
and computer test each one to ensure that they meet stringent
quality standards. And our case hardening furnaces add extra
toughness to the wear sensitive surfaces in the cover and driven plate. Contents Page
Clutch Drag 4
Computerised production control Clutch Judder 6
The latest technology has been integrated into all areas from design Clutch Noise 8
and development through computerised production control systems
Clutch Slip 10
to an advanced clutch testing laboratory.
Loss of Drive 12
2 3
C LU TC H D R AG
FAU LT FAU LT
Damaged Spline Cover assembly drive strap distorted
Difficulty in changing gear
C AU S E C AU S E
Incorrect alignment of gearbox input shaft Cover assembly dropped prior to fitment
"Bump" start engine in first or reverse gear
AC T I O N AC T I O N
Use alignment tool Ensure correct handling of the cover assembly
Lubricate sparingly Avoid "bump" starting of engine
FAU LT FAU LT
Driven plate distortion Clutch drag
Clutch drag Cover pressing distorted
C AU S E C AU S E
Gearbox allowed to "hang" during fitment allowing excess axial runout Cover assembly has not been fitted onto the flywheel dowels correctly
AC T I O N AC T I O N
Ensure gearbox is offered in line with the input shaft to reduce Check configuration of dowel holes and their relationship to the bolt holes
lateral movement prior to fitment of the cover assembly
FAU LT FAU LT
Clutch drag Clutch drag
C AU S E C AU S E
Diaphragm spring fingers broken. Release bearing rattling against diaphragm Driven plate fitted wrong way round
spring fingers. Gearbox/engine misalignment. Insufficient release bearing load
AC T I O N AC T I O N
Avoid damage to diaphragm spring fingers when replacing gearbox. Ensure correct configuration of the driven plate prior to fitment
Check release bearing mechanism is free. Ensure clutch is mounted
correctly on flywheel and location dowels in position
4 5
C LU TC H J UDD E R
FAU LT FAU LT
Clutch judder Clutch judder
Cover pressing distorted Sticking release mechanism
Damaged release bearing bore
C AU S E C AU S E
Cover assembly has not been fitted onto the flywheel dowels correctly Sticking clutch cable
Worn or seized clutch release mechanism
AC T I O N AC T I O N
Check configuration of dowel holes and their relationship to the bolt holes Ensure clutch cable is smooth in operation
prior to fitment of the cover assembly Ensure all release bearing mechanism parts are not worn or seized - replace
with new parts where necessary
FAU LT FAU LT
Clutch judder Clutch judder
Worn or glazed flywheel Misaligned release bearing
C AU S E C AU S E
Damaged surface on flywheel Bent release bearing fork or missing clips
Previous clutch worn past rivet depth Insufficient release bearing pre-load
AC T I O N AC T I O N
Check surface finish of flywheel for flatness 'machine' or replace as required Check for wear on all release bearing mechanism including cables, fork
locations, release shaft bushes
Ensure correct clutch settings
FAU LT FAU LT
Clutch judder Sticking release mechanism
Oil/grease contamination
C AU S E C AU S E
Excessive grease applied to the input shaft spline Warn release bearing guide
Oil leak from engine or gearbox Sticking clutch cable
Friction material contaminated with grease or oil prior to fitment Release bearing fitted incorrectly
AC T I O N AC T I O N
Only use grease supplied by QH Check for smooth operation of all moving parts of the release mechanism and
Rectify any oil leaks replace with new where necessary
Ensure friction material is clean prior to fitment
6 7
C LU TC H N O I S E
FAU LT FAU LT
Noisy clutch Clutch noise when disengaging
C AU S E C AU S E
Diaphragm spring fingers broken. Release bearing rattling against diaphragm Diaphragm spring is contacting driven plate
spring fingers. Gearbox/engine misalignment. Insufficient release bearing load Release bearing travel is excessive
AC T I O N AC T I O N
Avoid damage to diaphragm spring fingers when replacing gearbox. Ensure correct clutch adjustment
Check release bearing mechanism is free. Ensure clutch is mounted
correctly on flywheel and location dowels in position
FAU LT FAU LT
Clutch noise on disengagement Clutch noise
C AU S E C AU S E
Driven plate fitted wrong way round Release bearing fitted backwards
AC T I O N AC T I O N
Ensure correct configuration of the driven plate prior to fitment Ensure release bearing is fitted right way round with correct travel and
release load
FAU LT FAU LT
Broken springs Underside of diaphragm spring radially marked in one or more places
Clutch noise
C AU S E C AU S E
Incorrect alignment of engine and gearbox Release bearing travel is excessive causing the diaphragm spring to touch the
Incorrect design of clutch assembly fitted Worn input shaft driven plate
Excessive backlash in drivetrain
AC T I O N AC T I O N
Check wear on input shaft Ensure correct clutch assembly is fitted for the Ensure clutch release travel is correct
application Ensure engine and gearbox are fitted in line
Check wear in final drive, propshaft uj’s and C.V. joints
8 9
C LU TC H S L I P
FAU LT FAU LT
Clutch slip Clutch slip
Oil/grease contamination Overheated friction material
C AU S E C AU S E
Excessive grease applied to the input shaft spline Incorrect clamp load on clutch cover assembly
Oil leak from engine or gearbox Possible driver misuse by leaving foot on clutch pedal while driving
Friction material contaminated with grease or oil prior to fitment Sticking release bearing mechanism including cable
AC T I O N AC T I O N
Only use grease supplied by QH Ensure correct assembly is fitted to suit the application
Rectify any oil leaks Advise driver about clutch mechanics
Ensure friction material is clean prior to fitment Ensure release bearing mechanism is free - replace any worn parts
FAU LT FAU LT
Clutch slip Uneven wear across friction face
Friction material excessively worn
Uneven wear of friction material
C AU S E C AU S E
Sticking release mechanism or cable. Normal wear of life of clutch. Worn flywheel
Possible driver misuse - leaving foot on pedal while driving
Possible driver abuse
AC T I O N AC T I O N
Ensure release mechanism is free Check flywheel for wear and flatness renew if necessary
Replace clutch as per end of life
Advise driver about clutch mechanics
FAU LT FAU LT
Clutch slip Clutch slip
Facing material broken Evidence of overheating on pressure plate surface
C AU S E C AU S E
Friction material damaged prior to or during fitment Sticking clutch cable
Overheating due to slip Sticking release mechanism
Incorrect clutch fitted for the application. Possible driver abuse Possible driver misuse
AC T I O N AC T I O N
Handle with care Check clutch cable slides freely under load
Ensure correct clutch is fitted for the application Check clutch release mechanism
Rectify cause of slipping. Advise driver about clutch mechanics Advise driver about clutch mechanics
10 11
