User Guide

EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
EXEDY Globalparts Corporation • 800.346.6091 • www.exedyusa.com
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Malfunctions of Clutch Pressure Plate Cover Assemblies Malfunctions of Clutch Pressure Plate Cover Assemblies
PROBLEM: Oil or grease contamination on friction surface.
SYMPTOM: Slipping clutch/Judder.
CAUSE: Excessive grease or low viscosity grease causes
this problem.
Melted grease on friction material aected
friction coecient and caused slipping or judder.
SOLUTION: Lightly grease spline, wipe o excessive grease
after tentative installation and ensure there is
smooth sliding of clutch disc on main drive shaft.
PROBLEM: Discoloration on friction surface and/or clutch
cover.
SYMPTOM: Slipping clutch.
CAUSE: Extreme friction surface temperature rise and
slips under extreme clutch operation. This may
cause discoloration of clutch.
SOLUTION: Driver education not to activate the clutch in
excessive semi disengagement position.
PROBLEM: Warped clutch cover assembly by reuse.
SYMPTOM: Clutch drag.
CAUSE: Insucient contact due to warped pressure
plate. Only clutch disc was replaced which
caused partial contact on friction surface and
slipped during heavy load condition.
SOLUTION: Always replace a clutch disc, a clutch cover and
a clutch thrust release bearing when replacing
clutch system.
PROBLEM: Hold down bolts still in cover assembly.
SYMPTOM: Clutch slipping/Noisy clutch.
CAUSE: Clutch cover pressure plate assembly hold down
bolts to assist ease installation not removed.
SOLUTION: Remove hold down bolts painted in red. (Do not
remove clutch lever adjustment nuts which are
not painted in red)
PROBLEM: Mirror nish on pressure plate friction surface.
SYMPTOM: Judder.
CAUSE: 1. Friction surface may be ground by worn facing
bers as abrasive compound, if you keep clutch
slipping continuously i.e. hill start. It may cause
judder because of too good surface to become
mirror nish.
2. Clutch slave cylinder corroded or worn and
piston not returning freely.
SOLUTION: 1. Driver education not to activate the clutch in
an excessive semi disengagement position.
2. Replace slave cylinder..
PROBLEM: Burst pressure plate casting.
SYMPTOM: No drive/Noisy clutch.
CAUSE: 1. Over revving of engine that has exceeded
manufacturers’ specications.
2. Overheating of casting due to constant abuse
of clutch. The main spring has weakened through
extreme inuence of heat.
SOLUTION: 1. Do not use covers where engine has been
modied to excess manufacturer’s rpm
specication.
2. Driver education not to activate the clutch in
excessive semi disengagement position.
Remove hold down bolts
Mirror nish on pressure plate
Breakage of pressure plate
Grease on friction surface
Friction surface, cover discoloration
Pressure plate heat distortion