Indicator

Difficult to dis-engage gears

Cause

1. Insufficient lubrication of the clutch disc spline
2. Dirty/Contaminated splines on the gearbox

Effect

Dry splines on the clutch disc and red dust may be present

Action

1. Clean the input shaft splines removing any old grease or old clutch dust
2. Lubricate the splines (refer the fitting video https://www.youtube.com/watch?v=OrH7gCmjF-o)

» Link to Guide

Indicator:

Difficulties changing gears

Cause:

1. Gearbox misaligned (gearbox to engine dowels damaged or missing)
2. Input shaft damaged

Effect:

Spline damaged on the clutch disc from incorrect alignment

Action:

1. Replace clutch disc
2. Inspect gearbox to engine dowels are present and serviceable (if damaged replace)
3. Inspect the Input shaft for excessive wear and damage.

» Link to Guide

Indicator:

Difficulties changing gears

Cause:

1. Gearbox misaligned (gearbox to engine dowels damaged or missing)
2. Input shaft damaged

Effect:

Spline damaged on the clutch disc from incorrect alignment

Action:

1. Replace clutch disc
2. Inspect gearbox to engine dowels are present and serviceable (if damaged replace)
3. Inspect the Input shaft for excessive wear and damage.

» Link to Guide

Indicator:

Loss of dive/Poor clutch performance

Cause:

1. Engine to gearbox dowels missing or damaged
2. Gearbox and/or engine mounting face damaged or have high levels of contamination
3. Obstructions between engine and gearbox mounting face preventing the gearbox to be flush to the engine when mounted.
4. Missing/damaged or incorrectly torqued gearbox mounting bolts

Effect:

Clutch disc failure due to mis-alignment (gearbox centre off-axis to crankshaft)

Action:

1. Replace clutch kit
2. Replace gearbox dowels
3. Ensure the gearbox and engine mating surfaces are free from contamination.
4. Ensure there are no obstructions between engine and gearbox when final torqueing of the gearbox mounting bolts
5. Replace worn or damaged gearbox mounting bolts if necessary

» Link to Guide

Indicator:

Clutch fails to release/poor clutch performance

Cause:

1. Hanging the transmission on the clutch disc (not locating the gearbox over the dowels)

2. Incorrect gearbox mounting (forcing the gearbox onto the engine with the bolts)

Effect:

Bent clutch disc

Action:

1. Replace clutch disc/Clutch kit
2. Always practice safe installation of the transmission
3. Align the clutch disc to the engine with the correct clutch alignment tool.

» Link to Guide

Indicator:

Loss of drive/Noisy when operating the clutch pedal

Cause:

1. Clutch disc has been over torqued - example: down changing from 5th to 2nd gear at high speed
2. Severe engine to gearbox mis-alignment - Red dust will be present when alignment issues are present.
3. Clutch disc has been overloaded
4. Damaged pilot bearing/bush
5. Damaged upon fitment
 

Effect:

The disc outer has come off the drive hub

Action:

1. Replace the clutch disc
2. Check all engine to gearbox dowels are present and in a serviceable condition (If necessary replace)
3. Replace pilot bearing/bush
4. Show care when fitting the gearbox making sure there is no possibility of damaging the drive up causing the spring fatigue (hanging the gearbox on the clutch disc)
5. Driver education

» Link to Guide

Indicator:

Unable to disengage gears/Noisy clutch operation

Cause:

1. Clutch disc has been over torqued - example: down changing from 5th to 2nd gear at high speed
2. Severe engine to gearbox mis-alignment - Red dust will be present when alignment issues are present.
3. Damaged pilot bearing/bush
4. Damaged upon fitment

Effect:

Damaged torsion springs

Action:

1. Replace the clutch disc
2. Check all engine to gearbox dowels are present and in a serviceable condition (If necessary replace)
3. Replace pilot bearing/bush
4. Show care when fitting the gearbox making sure there is no possibility of damaging the drive up causing the spring fatigue (hanging the gearbox on the clutch disc)
5. Driver education

» Link to Guide

Indicator:

Difficult to disengage gears

Cause:

1. Poor fitting techniques (clutch disc not aligned correctly)
2. Forcing the gearbox onto the engine dowels (using bolts to force the gearbox to its mounting face)

Effect:

Damaged clutch disc splines

Action:

1. Use clutch alignment tool when fitting the clutch kit to the flywheel
2. Always show care when fitting the gearbox ensuring the clutch disc is not damaged

» Link to Guide

Indicator:

Difficulties disengaging gears

Cause:

1. Clutch disc has been damaged when fitting
2. Clutch disc has been dropped
3. Clutch disc has been damaged in transit

Effect:

Damaged facing material

Action:

1. Replace the Clutch Disc/Clutch kit
2. Always show care when fitting clutch discs
3. Always thoroughly inspect the clutch components prior to fitting.

» Link to Guide

Indicator:

Difficult to dis-engage gears

Cause:

1. Spline damaged when fitting the gearbox

Effect:

Burrs/Damage to the spline

Action:

1. Replace clutch disc
2. Align the clutch disc using clutch alignment tool
3. Use caution when fitting the gearbox ensuring no damage can occur

» Link to Guide