Inspection Procedure 2

INSPECTION PROCEDURE 2: Clutch Cannot be Disengaged

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 11.

STEP 2. Check the hydraulic system for leakage, air mix and clogging.

Q: Is there a leakage, air mix or clogging on the hydraulic system?
YES : Repair or replace the hydraulic system. Then go to Step 11.
NO [5M/T] : Go to Step 3.
NO [6M/T] : Go to Step 4.

STEP 3. Check the release fork for sticking.

Q: Is the release fork stuck?
YES : Repair or replace the release fork. Then go to Step 11.
NO : Go to Step 5.

STEP 4. Check the concentric slave cylinder for deformation.

Q: Is deformation found on concentric slave cylinder?
YES : Replace the concentric slave cylinder. Then go to Step 11.
NO : Go to Step 5.

STEP 5. Check the clutch disc for distortion and excessive oscillation.

Q: Is the clutch disc distorted or oscillating?
YES [5M/T] : Replace the clutch disc. Then go to Step 11.
YES [6M/T] : Replace the clutch disc and clutch cover assembly. Then go to Step 11.
NO : Go to Step 6.

STEP 6. Check the clutch disc spline for wear and corrosion.

Q: Is the clutch disc spline worn or corroded?
YES [5M/T] : Replace the clutch disc. Then go to Step 11.
YES [6M/T] : Replace the clutch disc and clutch cover assembly. Then go to Step 11.
NO : Go to Step 7.

STEP 7. Check the clutch disc facing for peeling.

Q: Is clutch disc facing peeling?
YES [5M/T] : Replace the clutch disc. Then go to Step 11.
YES [6M/T] : Replace the clutch disc and clutch cover assembly. Then go to Step 11.
NO : Go to Step 8.

STEP 8. Check the clutch cover assembly for wear.

Q: Is the clutch cover assembly worn?
YES [5M/T] : Replace the clutch cover assembly. Then go to Step 11.
YES [6M/T] : Replace the clutch disc and clutch cover assembly. Then go to Step 11.
NO : Go to Step 9.

STEP 9. Check the pressure plate and the flywheel for damage.

Q: Is the pressure plate or the flywheel damaged?
YES [5M/T] : Replace the clutch cover assembly or the flywheel. Then go to Step 11.
YES [6M/T] : Replace the clutch disc and clutch cover assembly or the flywheel. Then go to Step 11.
NO [5M/T] : Go to Step 10.
NO [6M/T] : Go to Step 11.

STEP 10. Check the clutch release bearing for wear.

Q: Is the clutch release bearing worn?
YES : Replace the clutch release bearing. Then go to Step 11.
NO : Go to Step 11.

STEP 11. Check again for the symptom.

Q: Is the symptom reproduced?
YES : Return to Step 1.
NO : The procedure is complete.