Clutch System Diagnosis
WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Clutch problem diagnosis will generally require a road test to determine the type of fault. Component inspection will then determine the problem after road testing.
Drive the vehicle at normal speeds during road test. Shift the transaxle through all gear ranges and observe clutch action. If chatter, grab, slip or improper release is experienced, remove and inspect the clutch components. If the problem is noise or hard shifting, further diagnosis may be needed. The transaxle or other driveline components may actually be at fault.
CLUTCH GRAB/CHATTER
| CONDITION | POSSIBLE CAUSES | CORRECTION |
|---|---|---|
| CLUTCH DISC FACING COVERED WITH OIL OR GREASE | Oil leak at engine rear main or transaxle input shaft seal. | 2.4L - Correct leak and replace modular clutch assembly. |
| - | 1.6L/Diesel/Turbo - Clean pressure plate, flywheel and replace clutch disc. | |
| - | Too much grease applied to splines of disc and input shaft. | Apply lighter coating of grease to splines. |
| NO FAULT FOUND WITH CLUTCH COMPONENTS |
Problem actually related to suspension or driveline component. | Further diagnosis required. Check engine/transmission mounts, suspension attaching parts and other driveline components as needed. |
| - | Engine related problems. | Check EFI and ignition systems. |
| PARTIAL ENGAGEMENT OF CLUTCH DISC | Clutch cover, spring or release fingers bent, distorted (rough handling, improper assembly). | Replace clutch assembly. |
| - | Clutch disc damaged or distorted. | Replace clutch assembly. |
| - | Clutch misalignment. | 2.4L and Turbo - Verify modular clutch pilot plate alignment to crankshaft. Replace the modular clutch assembly if the pilot plate is loose or bent. |
| - | 1.6L and Diesel - Check alignment and runout of flywheel, disc or cover. Check clutch housing to engine dowels and dowel holes for damage. Correct as necessary. |
CLUTCH SLIPS
| CONDITION | POSSIBLE CAUSES | CORRECTION |
|---|---|---|
| DISC FACING WORN OUT | Normal wear. | Replace clutch assembly. |
| - | Driver frequently rides (slips) clutch, results in rapid wear, overheating. | Replace clutch assembly. |
| - | Insufficient clutch cover diaphragm spring tension | Replace clutch assembly. |
| CLUTCH DISC FACING CONTAMINATED WITH OIL OR GREASE | Leak at rear main oil seal or transaxle input shaft seal | 2.4L - Replace leaking seals. Replace clutch assembly. |
| - | 1.6L/Diesel/Turbo - Replace leaking seals. Clean the pressure plate and flywheel surface and replace clutch disc. | |
| - | Excessive amount of grease applied to input shaft splines | 2.4L - Apply less grease to input shaft. Replace clutch assembly. |
| - | 1.6L/Diesel/Turbo - Apply less grease to input shaft. Clean the pressure plate and flywheel surface and replace clutch disc. | |
| - | Road splash, water entering housing | Seal housing. Inspect clutch assembly. |
| - | Concentric Slave Cylinder leaking hydraulic fluid | Replace Concentric Slave Cylinder (CSC) |
| CLUTCH IS RUNNING PARTIALLY DISENGAGED | Release bearing sticking or binding, does not return to normal running position. | Verify that bearing is actually binding. Then, replace bearing and transmission front bearing retainer if sleeve surface is damaged. |
| - | Clutch master cylinder pushrod not adjusted properly (LHD Models), causing high preload. | Verify that pushrod adjustment is correct (LHD Models). |
| Slave cylinder binding | Replace slave cylinder | |
| CLUTCH DISC FACINGS HAVE FRACTURED INTO SMALL PIECES | Driver performs a 5-1 downshift at vehicle speed in excess of 60 miles per hour | Alert driver to problem cause. Replace clutch assembly. Inspect slave cylinder, fork and bearing for damage. |
| - | Leak at rear main or transaxle input shaft seal | 2.4L - Replace seal. Replace clutch assembly. |
| - | 1.6L/Diesel/Turbo - Replace seal. Clean the pressure plate and flywheel surface and replace clutch disc. | |
| - | Excessive heat from slippage | Replace Clutch Assembly |
IMPROPER CLUTCH RELEASE
| CONDITION | POSSIBLE CAUSES | CORRECTION |
|---|---|---|
| CLUTCH DISC BINDS ON INPUT SHAFT SPLINES | Clutch disc hub splines damaged during installation | Clean, smooth and lubricate disc and shaft splines. Replace modular clutch assembly or clutch disc, and/or input shaft if splines are severely damaged. |
| - | Input shaft splines rough, damaged. | Clean input shaft splines. Then lube. |
| - | Corrosion or rust formations on splines of input shaft and disc | Clean input shaft splines and disc splines, then lube |
| CLUTCH DISC RUSTED TO FLYWHEEL AND/OR PRESSURE PLATE | Occurs in vehicles stored or not driven for extended period of time. Also occurs after steam cleaning if vehicle is not used for extended period. | Replace clutch assembly. |
| CLUTCH WILL NOT DISENGAGE PROPERLY | Disc bent, distorted during transaxle installation | Replace clutch assembly. |
| - | Clutch cover diaphragm spring damaged during transaxle installation | Replace clutch assembly. |
| - | Release lever bent, loose or damaged | Replace release lever if worn or damaged |
| - | Air in clutch hydraulic system. | Bleed clutch hydraulic system to purge air. |
| - | Clutch master cylinder or slave cylinder leaking | Check and replace master and/or slave cylinder |
| - | Master cylinder adjustable pushrod loose or damaged | Inspect. Tighten adjustment fastener or replace master cylinder. |
| - | Pushrod not retained to clutch pedal pin. | Inspect pushrod & busing. Replace as necessary. |
CLUTCH PEDAL NOISE
| CONDITION | POSSIBLE CAUSES | CORRECTION |
|---|---|---|
| CLUTCH PEDAL SQUEAKS WHEN DEPRESSED TO FLOOR | Pedal bushings worn out or inadequate lubrication | Replace or lubricate bushings |
| - | Clutch pedal return spring worn out | Lubricate or replace return spring |