Clutch System
WARNING: This page is about a different car, the 2009 Dodge Caliber. 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. | T355 equipped- Correct leak and replace modular clutch assembly. |
|
NOTE:
The BG6 clutch disc and cover are available only as a matched set. If the cover or disc must be replaced, do not replace only the disc or only the cover. BG6 equipped - Clean the flywheel, and install a new clutch disc/cover set. |
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| 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 | BG6 equipped - 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 | T355 equipped - Replace leaking seals. Replace clutch assembly. |
|
NOTE:
The BG6 clutch disc and cover are available only as a matched set. If the cover or disc must be replaced, do not replace only the disc or only the cover. BG6 equipped - Replace leaking seals. Clean the flywheel surface and install a new clutch disc/cover set. |
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| Excessive amount of grease applied to input shaft splines | T355 equipped - Apply less grease to input shaft. Replace clutch assembly. | |
|
NOTE:
The BG6 clutch disc and cover are available only as a matched set. If the cover or disc must be replaced, do not replace only the disc or only the cover. BG6 equipped - Apply less grease to input shaft. Clean the flywheel surface and install a new clutch disc/cover set. |
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| 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. |
| Concentric Slave cylinder (CSC) binding | Replace Concentric Slave cylinder (CSC) | |
| 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 and bearing for damage. |
| Leak at rear main or transaxle input shaft seal | T355 equipped - Replace seal. Replace clutch assembly. | |
|
NOTE:
The BG6 clutch disc and cover are available only as a matched set. If the cover or disc must be replaced, do not replace only the disc or only the cover. BG6 equipped - Replace seal. Clean the flywheel surface and replace clutch disc. |
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| 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. | |
| 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 |
CLUTCH PEDAL NOISE
| CONDITION | POSSIBLE CAUSES | CORRECTION |
|---|---|---|
| CLUTCH PEDAL SQUEAKS WHEN DEPRESSED TO FLOOR | Pedal bushings worn out or inadequate lubrication | Replace the Pedal assembly |
| Push rod ball joint worn out | Lubricate or replace the push rod | |
| Clutch pedal return spring worn out | Replace the Pedal assembly |