Inspection Procedure 2

INSPECTION PROCEDURE 2: Gear Shift Malfunction

DIAGNOSIS

STEP 1. Check the excessive clutch pedal play.
Q: Does the clutch pedal play meet the standard value?
YES: Go to Step 2
NO: Adjust the clutch pedal play. Then go to Step 9

STEP 2. Check the hydraulic system for air mix.
Q: Is there a leakage air mix on the hydraulic system?
YES: Bleed the system. Then go to Step 9
NO: Go to Step 3

STEP 3. Check the hydraulic system for leakage and clogging.
Q: Is there a leakage or clogging on the hydraulic system?
YES: Check the oil line and clutch master cylinder, and repair if necessary. Then go to Step 9
NO: Go to Step 4

STEP 4. Check the clutch release concentric cylinder for oil leaks or deformation.
Q: Is oil leak or deformation found on clutch release concentric cylinder?
YES: Replace the clutch release concentric cylinder. Then go to Step 9
NO: Go to Step 5.

STEP 5. Check the clutch disc for distortion and wear.
Q: Is the clutch disc distorted or worn?
YES: Replace the clutch disc Then go to Step 9
NO: Go to Step 6.

STEP 6. Check the clutch disc spline for wear and corrosion.
Q: Is the clutch disc and input shaft spline worn or corroded?
YES: Replace the clutch disc or input shaft. Then go to Step 9
NO: Go to Step 7

STEP 7. Check the clutch cover assembly for damage.
Q: Is the clutch cover assembly damaged?
YES: Replace the clutch cover assembly. Then go to Step 9.
NO: Go to Step 8.

STEP 8. Check the pressure plate and the flywheel for damage.
Q: Is the pressure plate or the flywheel damaged?
YES: Replace the clutch cover assembly or the flywheel. Then go to Step 9.
NO: Go to Step 9

STEP 9. Check the symptom.
Q: Is the symptom reproduced?
YES: Return to Step 1
NO: This diagnosis is complete.