Clutch Master And Clutch Slave Cylinder, Checking

Before replacing master or slave cylinder, the corresponding tests must be performed in the event of the following problems.

Noises when Pressing the Clutch:

• First check the over-center spring or the clutch pedal switch for noises.
• If there are noises, remove the over-center spring and repeat the test.
• Replace the affected component.

Clutch Pedal Remains on Floor or Does Not Return to Rest Position After Recoupling (Clutch Pedal No Longer Actuated):

• Check whether clutch pedal returns completely to rest position. This frees the bleeder hole in clutch master cylinder.
• Make sure the footwell trim panels or floor mats are not in the way.
• Advise the customer not to leave the clutch pedal pressed.
• It can interfere with the self-bleeding function of the clutch system, because the bleeder hole in the clutch slave cylinder cannot perform its function.
• The clutch hydraulics is self-bleeding only if the bleed hole is unobstructed.
• The bleeder hole is integrated inside the clutch slave cylinder. It is visible from the outside.

Check the Entire Hydraulic System for Leaks.

• First check the brake fluid level in the brake fluid reservoir.
• Visually inspect the clutch master and slave cylinders as well as hose/line assembly with its connecting points for leaks to outside.
• Replace any leaking components.
• Bleed the clutch system. Refer to CLUTCH MECHANISM, BLEEDING .

High Pedal Force:

• The pressure plate or clutch plate is mechanically faulty. Refer to OVERVIEW - CLUTCH .

Pedal Force:

Single disc SAC clutch:

- approximately 140 Nm over entire life of clutch

Two-disc SAC clutch:

- approximately 125 Nm over entire life of clutch

Clutch Does Not Disengage or Does Not Disengage Completely:

• Air in the hydraulic system, bleed the clutch system (refer to CLUTCH MECHANISM, BLEEDING ) or check the hydraulic system for external and internal leakage
• The clutch plate is difficult to move on the splines of the input shaft.
• If the needle bearing inside the drive plate (centering bearing for the input shaft) is faulty, replace it. Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING for 3.0L, engine codes CCBA, CGXC, CTUB .
• Foreign body in the clutch system.
• The clutch pressure plate or clutch plate is mechanically faulty. Refer to OVERVIEW - CLUTCH .
• During repair work, the wrong parts have been installed or parts have been forgotten (for example the intermediate plate, the alignment sleeves between the engine and transmission).