User Guide

EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
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EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
26
Malfunctions of Clutch Discs
PROBLEM 1: Stripped out or wore teeth on spline.
PROBLEM 2: Cushion spring steel segments separated from
hub area.
SYMPTOM: Noisy clutch/unable to drive.
CAUSE: Misalignment between engine crank shaft and
transmission main drive shaft during installation
of transmission.
Excessive force to t main drive shaft causes this
problem during reinstallation of transmission.
SOLUTION: During the installation of transmission, align
drive line,
-height
-angle
-spline teeth
then t without excessive force.
Exchange the deteriorated pilot bearing or bush
parts after removal of contamination or scratch
on the mating surface of bell housing.
PROBLEM: Oily Facings.
SYMPTOM: Slipping clutch/shuddering/juddering clutch.
CAUSE: 1. Faulty main drive oil seal.
2. Faulty rear main bearing oil seal.
SOLUTION: 1. Replace clutch disc.
2. Replace faulty oil seals.
PROBLEM: Dicult gear engagement/broken rubber
dampeners.
SYMPTOM: Noisy, no disengagement (rubber torque
stopper type clutch disc).
CAUSE: 1. Use of inferior or imitation clutch disc.
2. Clutch wound past torque capacity.
3. Inferior rubber compound.
SOLUTION: 1. Fit genuine EXEDY/Daikin clutch.
2. Driver education.
Malfunctions of Clutch Discs
PROBLEM: Power not transmitting to drive train because
of broken facings.
SYMPTOM: No drive, noisy clutch.
CAUSE: Parts of the disc friction material are broken from
rivet along with part of the cushioned segment.
This is due to down shifting of gear i.e. the speed
of the vehicle at the rear wheels was travelling
faster than the engine RPM, when gear was
changed down.
SOLUTION: Driver education.
PROBLEM: 1. Crashing noise in gear box, non release.
2. Warped and bent clutch disc.
SYMPTOM: Dicult gear change.
CAUSE: 1. Hanging of gear box during installation.
2. Not aligning clutch disc and forcing main drive
into the spline, therefore, bending the clutch disc
hub towards the engine as seen in photo.
Note: Hanging the gear box during installation
pulls the clutch disc hub towards the gear box.
3. Driver resting foot on clutch pedal causing
clutch slip due to clutch being in a semi
disengaged position. This has caused extreme
heat which has warped the disc.
SOLUTION: 1. Do not hang gear box during clutch
installation. Always use a clutch aligning tool.
2. Do not force gear box into clutch disc spline.
3. Driver education/check free travel.
Stripped Out Spline
Separated clutch disc assembly