Inspection Procedure 2

INSPECTION PROCEDURE 2: Gear Shift Malfunction

DIAGNOSIS
Step 1. Check for 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 air mix in 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 leakage or clogging in 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 cylinder for oil leaks or deformation.
Q: Is oil leakage or deformation found on clutch release cylinder?
YES: Replace the clutch release 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: The procedure is complete.