Troubleshooting

GENERAL INFORMATION.

Before repairing the clutch, transmission, or related

actuation controls (except for obvious failures), carefully analyze the symptoms and their possible causes. A common external sign of clutch and manual transmission faults

is difficult gear shifting (high force on the shift lever,

gears engaging with a jolt, or grinding of the dog clutches) or gears jumping out. For difficult gear shifting, first check the clutch pedal travel and clutch disengagement. If necessary, adjust the clutch pedal travel.

Clutch pedal travel.

PROCEDURE.

Check the clutch actuation for play in the joints or worn

pivots, bracket deformation, cable damage, and other defects

that hinder pedal movement or reduce the clutch fork travel.

Checking clutch disengagement.

PROCEDURE.

1. The engine runs at idle speed, the transmission is in neutral, and the clutch is engaged.

2. Disengage the clutch, wait 9 seconds, and engage reverse gear. There should be no gear grinding noise. Grinding when engaging reverse gear indicates

incorrect adjustment or a fault in the clutch actuation, warped driving or driven discs,

or damage to clutch components, such as damper springs, friction linings, or driven disc cushioning elements,

diaphragm spring fingers, or pressure plate drive plates.