Indicator:

Noise, difficulties changing gears

Cause:

Broken drive hub on clutch disc/Damaged stop pins

Effect:

1. Severe engine to gearbox mis-alignment
2. Excessive down shifting (Changing from 5th to 2nd at high speed)
3. RPM overload of the clutch disc (High RPM launching)

Action:

1. Replace clutch disc
2. Check engine to gearbox dowels are present and in a serviceable condition (Replace if necessary)
3. Driver education.

» Link to Guide

Indicator:

Sudden Clutch Failure.

Cause:

1. Faulty or worn pilot bearings or bushing
2. Hanging gear box during installation
3. Contamination between mating surfaces of the engine bolt up areas.
4. Severe engine to gearbox mis-alignment
5. Clutch disc overload (Shifting from 5th to 2nd at high speed)
6. Transmission failure

Effect: 

Clutch hub failure.

Action:

1. Check pilot bearing and replace if necessary.
2. Inspect engine to gearbox dowels are serviceable and if damaged replace
3. Align clutch to the flywheel and show care when fitting the gearbox.
4. Ensure the engine and gearbox have clean mating surfaces before installation.
5. Check gear box for metal fragments then remove and repair parts in necessary.
6. Driver education

» Link to Guide

Indicator:

No drive

Cause:

1. Overloading the clutch disc (example: shifting from 5th to 2nd at high speed)

Effect:

Clutch disc lining broken

Action:

1. Replace clutch disc
2. Driver education

» Link to Guide

Indicator:

Loss of drive

Cause:

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

2. Input shaft damaged

Effect:

Spline worn/damaged or missing

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 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