To remove the clutch assembly, the clutch cover
attaching bolts are removed from the flywheel. Then, the
pressure plate assembly and clutch disc are removed from
the flywheel.
The flywheel and pilot bearing should be checked for
defects. A worn or damaged pilot bearing should be
replaced. An overheated or warped flywheel can be resur-
faced by a machine shop. The flywheel ring gear teeth
should be checked for damage. A damaged ring gear can
be removed. The replacement ring gear is installed by
heating it and placing it over the flywheel.
The clutch disc is almost always replaced during a
clutch teardown. The disc can be checked to determine
the cause of failure. This may help avoid a similar clutch
failure in the future.
Always check the new disc to make sure it is the proper
replacement. Many clutch problems after overhaul are
caused by using the improper clutch disc.
The pressure plate assembly is usually replaced as
part of a clutch overhaul. Some assemblies can be rebuilt.
The rebuilding process requires the use of a press.
The throwout bearing should be checked for
roughness and lack of grease. Always replace a throwout
bearing that shows any sign of defects. The throwout
bearing can be pressed from its collar, and a new bearing
can be installed. The clutch fork should be checked for
wear. Worn forks should be replaced.
Clutch housings do not wear out, but they should be
checked for cracks and warping. The housing may contain
a ball stud for the clutch fork. The stud should be checked
for wear and replaced if necessary.
When reassembling the clutch, always make sure your
hands are free from oil. Oil or grease on the clutch disc will
cause grabbing or slippage. A pilot shaft should be used to
ensure the disc hub splines and pilot hole line up closely. If
proper alignment is not obtained, the transmission will be
difficult to install. The clutch cover attaching bolts should
always be tightened with the pilot shaft in place.
After the clutch and other drive train parts are
reinstalled, the clutch pedal free play should be adjusted to
specifications. Road test the vehicle as the final step.
Review Questions—Chapter 7
Please do not write in this text. Place your answers on
a separate sheet of paper.
1. Explain what the phrase riding the clutch means.
What effect can it have on the clutch over time?
2. Which of the following items concerning the phrase
dumping the clutch is not true?
(A) Pressure plate apply springs engage gradually.
(B) Means increasing engine speed and then suddenly
releasing the clutch pedal.
(C) Causes instant heat buildup on clutch disc facings
and places tremendous stress on the drive train.
(D) Is a form of clutch abuse.
3. Vibration that occurs when the clutch is being
engaged or disengaged is called _____.
4. A deep knocking noise that is similar to an engine
main or rod bearing knock is an indication of _____.
(A) defective bearings
(B) a loose clutch fork
(C) weak retracting or cushion springs
(D) loose flywheel attaching bolts
5. Clutch adjustment involves _____.
(A) resurfacing the flywheel
(B) rebuilding the pressure plate assembly
(C) setting clutch free play
(D) All of the above.
6. Why should you not let a transmission hang after
removing its mounts?
7. Briefly cite two methods that may be used to remove
a pilot bearing from the crankshaft bore.
8. The flywheel face and pressure plate should be
cleaned with a(n) _____ cleaner.
9. When inspecting a flywheel, what trouble signs
should you look for?
10. Briefly summarize typical steps involved in the clutch
reassembly process for a front-engine, rear-wheel
drive vehicle.
ASE-Type Questions—Chapter 7
1. Each of the following operator actions can cause early
clutch failure except:
(A) riding the clutch pedal.
(B) disengaging the clutch when decelerating.
(C) dumping the clutch.
(D) overloading the vehicle.
2. Technician A says that light clutch drag can cause
gear clashing. Technician B says that clutch disc
spindown can be mistaken for clutch drag. Who
is right?
(A) A only.
(B) B only.
(C) Both A and B.
(D) Neither A nor B.
3. Technician A says that some clutch slippage is neces-
sary for smooth shifts. Technician B says that an oil-
soaked clutch disc will slip, even if it is not worn.
Who is right?
(A) A only.
(B) B only.
(C) Both A and B.
(D) Neither A nor B.
154 Manual Drive Trains and Axles