User Guide

EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
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EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
32
Malfunctions of Clutch Discs Malfunctions of Clutch Discs
PROBLEM: Torsion dampener stopper springs thrown
out of side plate/stop pins worn.
SYMPTOM: Noisy clutch/unable to engage or
disengage gear.
CAUSE: 1. Improper driving practice i.e. “dropping” the
clutch whilst engine is turning at extremely high
revolutions.
2. Down changing of gears i.e. 5th gear to 2nd
gear by low speed/high driving gear method.
3. Wear on the stop pins indicates the clutch
plate has been wound past specied torque
loading. This has the same aect on the springs.
4. Misalignment.
SOLUTION: 1. Driver education.
2. Refer misalignment tips
3. Vehicle used for performance driving. It
is advisable to use clutch disc with higher
stopper torque capacity. Refer EXEDY/Daikin
Performance/Sports Clutch listings.
PROBLEM: Torque stopper springs broken. Dicult gear
engagement which may lead to clutch failure.
SYMPTOM: Noisy clutch with vibration.
CAUSE: 1. Misalignment between engine crank-shaft
centre and gearbox main drive.
2. If the torsion springs are damaged along with
the torque stopper pin then it is evident that the
clutch has been wound past its torque capacity.
SOLUTION: 1. Refer misalignment tips.
PROBLEM: Clutch drag leading to total clutch failure. Signs
of red dust on clutch disc as seen in photo.
SYMPTOM: Clutch inoperative.
CAUSE: Severe misalignment between the mating
surfaces of the bell house and the rear of motor.
SOLUTION: 1. Refer misalignment tips.
2. Engine and gearbox modications where
mating surfaces are not parallel or the engine
and gear box do not mate at an absolute centre
line are to be rectied.
3. Metal dust cover plates overlapping each other
during installation must be avoided.
PROBLEM: Melted grease on clutch disc side plate.
SYMPTOM: Clutch shudders/judders and/or slips.
CAUSE: 1. Excessive grease on transmission input shaft.
2. Melted grease on friction material will aect
friction coecient of disc facing.
SOLUTION: 1. Lightly grease spline, wiping of excessive
grease and ensure there is smooth sliding of
clutch disc on main drive.
2. Replace clutch disc with new disc unit.
3. Use only high melting point grease.
PROBLEM: Wrong type of lubrication on input shaft spline.
SYMPTOM: Clutch shudders/judders and/or slips.
CAUSE: 1. On this example the wrong grade of grease
was used, aecting the friction coecient of the
disc material.
2. Over greasing of transmission input shaft
during installation.
SOLUTION: 1. Use specied grade of grease of vehicle
manufacturer (high melting point grease). Do
not use anti-seize.
2. Replace clutch disc with new disc unit.
3. Proper installation practice.