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How To Solve The Clutch Failure? These Four Steps Are Enough

For manual vehicles, the state of clutch plate will directly affect the vehicle power performance of clutch failure of clutch failure.

During daily maintenance, we often judge whether the clutch plate should be replaced by the following methods:

1. Vehicle climbing is boring of clutch failure.

2. When the vehicle is accelerating, the engine speed increases rapidly, but the vehicle speed can’t go up of clutch failure..

3. Shift into gear 1, pull the hand brake or step on the brake to start, but the vehicle does not turn off of clutch failure..

4. Open the engine compartment cover and you can smell the obvious burnt smell. The closer you are to the junction of engine and transmission, the heavier the burnt smell is of clutch failure..

The replacement cycle of clutch three-piece set varies from vehicle to vehicle. According to the normal loss, it can be used for about 100000 kilometers. Of course, after doing auto repair for so many years, they often come into contact with vehicles that are replaced after 50000 or 60000 kilometers. As for why, it must be what the owner wants to know most of clutch failure..

In fact, it is because the use method of clutch is not standard, resulting in frequent failures such as slipping, incomplete separation, shaking, abnormal noise and so on.

In the process of replacing the clutch three-piece set, the most painful thing is the installation of the clutch plate (after all, the position of the clutch plate directly affects the maintenance quality).

Don’t panic, Xiaobian is here to recommend you an easy-to-use tool —– clutch alignment tool!

It can not only improve the maintenance efficiency, but also ensure the maintenance quality. If you don’t have one, make arrangements and prepare one!

Of course, for these common faults of the clutch, we should know its nature and why! In order to achieve a targeted goal and win in stability.

Ko Clutch Failure Slipping

Fault Phenomenon:

① When starting in 1st gear, the car cannot start smoothly after releasing the clutch pedal of clutch failure..

② When accelerating, the vehicle speed can not increase with the increase of engine speed, feel weak driving, and produce burning smell or smoke in serious cases of clutch failure.

③ During the start-up test, the engine should have stalled, but it did not.

Possible causes:

① The free stroke of the clutch pedal is too small or there is no free stroke of clutch failure.

② The connection between the clutch pressure plate and the flywheel is loose, weakening the pressing force of clutch failure.

③ The oil contamination between the release bearing sleeve and the guide pipe is serious, so that the release bearing cannot return of clutch failure.

④ The surface of the clutch plate is ablated, hardened or greasy, resulting in reduced clutch friction.

⑤ The working surface of clutch plate, pressure plate or flywheel is seriously worn.

⑥ The pressure spring is weak or broken, and the diaphragm spring is weak or cracked, reducing the compression force.

Maintenance steps:

① First, check whether the free stroke of the clutch pedal is appropriate and adjust it if it is not suitable. (hydraulic type is mostly self-adjusting)

Then remove the transmission, disassemble the clutch and check it in turn

② If there is oil stain on the clutch plate, release bearing sleeve and guide pipe, it shall be cleaned in time.

③ The working surface of clutch plate, pressure plate or flywheel is worn. If it is seriously worn, it shall be replaced in time.

④ Whether the pressure spring and diaphragm spring are weak, broken or lack of elasticity. If the elasticity is insufficient or damaged, they shall be replaced in time.

Ko Clutch Is Not Fully Disengaged

When the clutch pedal is pressed at idle speed, there is a gear impact sound when engaging, and it is difficult to engage;

Sometimes it is forced to shift into gear, but the engine stops when the clutch pedal is not fully released.

① Excessive free travel of clutch pedal.


② Oil leakage from the hydraulic system causes insufficient oil or air intrusion. (hydraulic)


③ The newly replaced clutch plate is too thick or the front and back of the clutch plate are installed incorrectly (the convex side faces the transmission).


④ The pressure plate steel plate is warped, the friction plate is broken or the rivet is loose.


⑤ The height of the inner end of the separating lever is difficult to adjust due to improper adjustment of the separating lever, bending and deformation of the separating lever, looseness of the support and detachment of the support shaft pin.

① Check whether the free stroke of the clutch pedal is appropriate. If the free stroke is too large, adjust it.

② Check whether the hydraulic system pipelines and pipe joints leak oil.

③ Check whether the installation direction of the clutch plate is correct. If it is deformed or damaged, replace it in time.

④ Check whether the release lever is deformed, whether the support is loose and whether the release lever is properly adjusted.

⑤ Check whether the first shaft of the transmission fits well with the clutch driven plate. If it does not fit properly, adjust it in time.

Ko Clutch Abnormal Noise

Fault phenomenon:

When the vehicle starts or shifts gears, there is abnormal noise when operating the clutch.

Possible causes:

① Pedal return spring is too soft, falling off or broken.

② The rivet on the clutch plate is loose or the damping spring is broken.

③ The release bearing is seriously worn or short of oil, and the bearing return spring is too soft, broken or falling off.

① If you hear a “rustling” sound when slightly pressing the clutch pedal, and the sound disappears after lifting, it is the sound of the release bearing.

② If the clutch pedal still rings after lifting, the bearing is worn, loose or damaged, which shall be replaced;

③ If the clutch pedal is pressed / lifted, the support spring shall be replaced;

Ko Clutch Trembles When Starting

Possible causes:

① The surface of the clutch pressure plate or clutch plate is warped, or the rivets of the driven plate are loose;

② The fixing bolts of transmission and flywheel housing or clutch pressure plate and flywheel are loose;

③ The spring force of the damping spring on the clutch plate is uneven.

Maintenance steps:

① Check whether the fixing screws of transmission and flywheel housing, clutch cover and flywheel are loose.

② Check whether the height of diaphragm spring on clutch pressure plate is consistent.

③ If the above items meet the requirements, remove the clutch and check whether the pressure plate and clutch plate are deformed, whether the rivets are loose and whether the elastic force of diaphragm spring is within the allowable range.

In addition to the moves of the above four rounds, what unique skills do you have? Please leave a message and share it!

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