Diagnosis Table
WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
The Diagnosis Table below describes common clutch problems, causes and corrections.
DIAGNOSIS
| CONDITION | POSSIBLE CAUSES | CORRECTION |
|---|---|---|
| Disc facing worn out. | 1. Normal wear. | 1. Replace cover and disc. |
| 2. Driver frequently rides (slips) the clutch. Results in rapid overheating and wear. | 2. Replace cover and disc. | |
| 3. Insufficient clutch torque capacity. | 3. Replace cover and disc. | |
| Clutch disc facing contaminated with oil, grease, or clutch fluid. | 1. Leak at rear main engine seal or transmission input shaft seal. | 1. Replace appropriate seal. Replace clutch cover and disc if they have been contaminated. |
| 2. Excessive amount of grease applied to the input shaft splines. | 2. Remove grease and apply the correct amount of grease. Replace clutch cover and disc if they have been contaminated. | |
| 3. Concentric Slave Cylinder leaking. | 3. Replace the Concentric Slave Cylinder (CSC) and inspect hydraulic clutch lines. Replace clutch cover and disc if they have been contaminated. | |
| Clutch is running partially disengaged, or slips while driving. | 1. Release bearing sticking or binding and does not return to the normal running position. | 1. Verify failure. Replace the release bearing and transmission front bearing retainer as necessary. |
| 2. Release lever installed incorrectly. | 2. Check for proper installation of release lever. | |
| 3. Automatic wear adjustment incorrect. | 3. Replace clutch cover and disk. | |
| Facing on flywheel side of disc torn, gouged or worn. | 1. Flywheel surface scored or nicked. | 1. Correct surface condition if possible. Replace flywheel, clutch cover, and disc as necessary. |
| 2. Clutch disc sticking or binding on transmission input shaft. | 2. Inspect components and correct/replace as necessary. | |
| Clutch disc facing burnt. Flywheel and cover pressure plate surfaces heavily glazed. | 1. Frequent operation under high loads or hard acceleration conditions. | 1. Replace flywheel, clutch cover and disc. Alert driver to problem cause. |
| 2. Driver frequently rides (slips) clutch. Results in rapid wear and overheating of disc and cover. | 2. Replace flywheel, clutch cover and disc. Alert driver to problem cause. | |
| Clutch disc binds on input shaft splines. | 1. Clutch disc hub splines damaged during installation. | 1. Replace clutch disc. |
| 2. Input shaft splines rough, damaged, or corroded. | 2. Clean and lubricate shaft splines if possible. Replace input shaft if necessary. | |
| Clutch disc rusted to flywheel or pressure plate. | 1. Clutch not used for an extended period of time (e.g. long term vehicle storage). | 1. Replace clutch cover and flywheel if necessary. |
| Pilot bearing seized, loose or rollers are worn. | 1. Bearing cocked during installation. | 1. Install a new bearing. |
| 2. Bearing defective. | 2. Install a new bearing. | |
| 3. Bearing not lubricated. | 3. Install a new bearing. | |
| 4. Transmission misalignment. | 4. Check engine block and transmission housing for damage to alignment pins or alignment holes. Check input shaft for looseness/ wobble. Replace worn or loose parts as necessary. Install and lubricate a new bearing. | |
| Clutch will not disengage properly. | 1. Low hydraulic linkage fluid level. | 1. Add hydraulic linkage fluid. |
| 2. Clutch cover loose. | 2. Follow proper bolt tightening procedure. | |
| 3. Clutch disc bent or distorted. | 3. Replace clutch cover and disc. | |
| 4. Clutch cover diaphragm spring bent or warped. | 4. Replace clutch cover and disc. | |
| 5. Clutch disc installed backwards. | 5. Remove and install clutch disc correctly. | |
| 6. Release fork bent or fork pivot loose or damaged. | 6. Replace fork or pivot as necessary. | |
| 7. Clutch master or slave cylinder failure. | 7. Replace hydraulic linkage assembly and inspect clutch disc for contamination. Replace clutch cover and disk if contaminated by fluid. | |
| 8. Incorrect slave cylinder installed. | 8. Install correct slave cylinder. | |
| Clutch pedal squeak. | 1. Pivot pin loose. | 1. Tighten pivot pin if possible. Replace clutch pedal if necessary. |
| 2. Master cylinder bushing not lubricated. | 2. Lubricate master cylinder bushing. | |
| 3. Pedal bushings worn out or cracked. | 3. Replace and lubricate bushings. | |
| 4. Rough surface on front bearing retainer. | 4. Replace front bearing retainer. | |
| Clutch master or slave cylinder plunger dragging or binding | 1. Master or slave cylinder components worn or corroded. | 1. Replace clutch hydraulic linkage assembly. |
| Release bearing is noisy. | 1. Release bearing defective or damaged. | 1. Replace release bearing. |
| Contact surface of release bearing damaged. | 1. Release bearing defective or damaged. | 1. Replace the release bearing. |
| 2. Release bearing misaligned. | 2. Check front bearing sleeve for damage/alignment. Repair as necessary. | |
| 3. Wear or discoloration at the bearing to clutch interference is acceptable. | 3. Re-install bearing and continue usage. |