Possible causes of malfunction | Remedy |
Clutch pedal does not return to its original position | |
Air in the line, low brake fluid level | Add brake fluid, bleed the lines |
Seizure of pistons in the main or working cylinders. Leaks in the line, in the main or working cylinders | Replace the defective part, bleed the highway system |
out of order (in the presence of) return spring | Replace return spring |
Difficult shifting of gearbox elements | Clean and lubricate bearings, repair bearing assemblies if necessary |
Difficulty moving elements in the clutch housing | Clean and lubricate bearings, repair bearing assemblies if necessary |
Misalignment, jamming of the release bearing on the guide sleeve | Replace guide bushing and release bearing |
Breakage of the disk spring of the pressure plate | Replace pressure plate |
Great effort on the clutch pedal | |
Stiff clutch pedal. Before checking, disconnect the master cylinder from the clutch pedal | Clean and lubricate bearings, repair bearing assemblies if necessary |
Hard travel of the toggle spring support. Toggle spring defective | Clean and lubricate bearings, repair bearing assemblies if necessary. Replace flip spring |
Too strong return spring (in the presence of), non-standard return spring | Make identification according to the spare parts catalog |
Increased clutch release force due to worn friction linings | Replace the clutch disc if the gap between the lining and the rivets is less than 0.1 mm |
Difficulty moving elements in the clutch housing | Clean and lubricate the supports, replace the support bushings if necessary |
Misalignment, jamming of the release bearing on the guide sleeve | Replace defective parts |
The contact surfaces of the release bearing/clutch release lever have worn out | Replace defective parts |
Pressure plate with incorrectly identified springs | Make identification according to the spare parts catalog |
The driven disk runs hard / sticks in the splines | Check hub splines for damage (burrs), if necessary, replace the driven disk. Clean the hub splines and input shaft of rust and grease residues and apply grease to them. Move the driven disc to remove excess grease |
Only for manual transmission 02K: Difficulty moving the clutch rod and release plate (belleville spring) | Apply a thin coat of grease to the contact points. Apply a thin layer of grease to the clutch rod |
Noises when pressing the clutch pedal | |
Difficulty moving the clutch pedal, broken bearing surfaces. The changeover spring support is dry, has a difficult course. broken | Clean and lubricate bearings, repair bearing assemblies if necessary |
return spring (in the presence of) causes noise | Apply grease to bearing surfaces |
Defective release bearing, defective release bearing guide, wear on contact surfaces | A noisy release bearing must usually be replaced. Replace guide bushings if damaged |
Contact surface damaged (the ends of the petals of the Belleville spring) pressure plate (bent, broken). The axis of rotation of the release bearing is shifted | Replace pressure plate. Check release bearing and guide sleeve, replace if necessary. Check the position of the clutch release lever. Check the centering sleeves |
Defective needle bearing in crankshaft (in the presence of). skew (bias) axles of the engine/gearbox | Lubricate tappet end with MoSe based grease Check centering bushings |
Driven disc installed in wrong position | Correct the installation position |
Clutch disc installed | Make identification according to the spare parts catalog |
Grinding sound when shifting into forward or reverse gear, gear shifting sticks, stalls, is difficult to change gear, the clutch does not work | |
The brake fluid level is below normal. Air in the system, clutch does not fully disengage | Check the system, add brake fluid, bleed the system |
The main or working cylinders or the line are leaking, the aging of the indicated nodes, the line is too elastic | Replace defective parts, add brake fluid, bleed the system |
The pressure plate is uneven due to incorrect installation, the driven plate is warped due to improper handling | Check the parts, replace if necessary, check the position of the centering pins. If after that a rattle is heard, check the spline connection of the driven disk and the input shaft for freedom of movement, check the needle bearing of the crankshaft, if necessary, repair the gearbox |
Broken or bent ends of the Belleville spring petals (assembly defect, the release bearing axis is displaced) | Replace pressure plate. Check release bearing, guide sleeve, replace if necessary. Check the centering sleeves |
Only for manual transmission 02K Stem has become too short due to wear | Replace the stem, check the release bearing, replace if necessary. Lightly grease the release bearing shaft with grease |
Too big thickness of a conducted disk | Make identification according to the spare parts catalog |
Cover rusted to flywheel (after a long stay, from high humidity) | Slightly grind the rubbing surfaces of the driven disc linings or, in case of severe corrosion, replace parts |
The driven disk is tight / sticks in the splines. The hub is corroded, damaged during installation. Hub hole broken on one side | Check the splines of the hub for damage, if necessary, replace the driven disk. Remove rust and grease from the bushing and shaft. Lightly lubricate the shaft with grease. Move the driven disc to remove excess grease. If the hub hole is broken, check the position of the centering bushings. Check release bearing, guide sleeve, pressure plate and needle bearing, replace if necessary |
Movement of the pressure plate when retracting is not enough (installed non-standard pressure plate) | Make identification according to the spare parts catalog |
Defective needle bearing in crankshaft (in the presence of). Crankshaft «leads» primary with clutch depressed | Replace needle bearing and lubricate with MoS2 based grease. Check the centering sleeves, replace if necessary. Check input shaft |
Increased mutual displacement of the engine / gearbox block (no centering bushings), in connection with which the bearing part of the clutch disc is deformed. Defective needle bearing in crankshaft (in the presence of) | Before installing the gearbox, insert the centering sleeves. Check the driven plate, pressure plate and needle bearing for damage, replace if necessary |
Breakage or chipping of linings due to increased speed (downshifting at too high a speed). Detachment or chipping of linings due to prolonged slippage when starting off | Replace driven disk |
Shock loads during hard acceleration and sudden deceleration | |
Insufficient rigidity of the suspension of the power unit | Make identification according to the spare parts catalog. Replace if necessary |
Uneven engine operation | Check engine adjustment, make adjustments |
Defective needle bearing in crankshaft (in the presence of). skew (bias) axes of the motor' gearbox | Replace needle bearing and lubricate with MoS2 based grease. Check centering bushings, replace if necessary |
Clutch slips, vehicle pulls poorly or no traction | |
The rod of the main or working cylinder does not return to its original position | Replace master or slave cylinder. Change the brake fluid, bleed the system |
Non-standard driven or pressure plate installed | Make identification according to the spare parts catalog |
Wear or burning of the driven plate, overheating of the pressure plate, risks, misalignment of the pressure plate due to improper installation, lack of pressure plate pressure, driving errors, normal wear and tear | Replace driven disk. Replace pressure plate |
Difficulty shifting gearbox elements. Difficulty moving the pedal on the pedal assembly | Clean and lubricate bearings, repair if necessary |
The driven disk, pressure disk, flywheel are oiled. Damaged seals on the shafts of the engine or gearbox. Lubrication on the working surfaces of the discs due to excessive lubrication of the hub of the driven disc | Replace driven disk. Clean the working surfaces, pressure plate and flywheel. Replace seals on shafts, remove excess grease from input shaft |
Only for manual transmission 02K. Main shaft seal ring leaking. Knocked out the bushing of the rod support in the input shaft | Replace O-ring, driven disc. Check and, if necessary, replace the stem support bushing. Clean pressure plate, flywheel |
Driven disc installed in wrong position | Correct the installation position, check the driven disk, replace if necessary |
Too thick flywheel or increased wear of lining surfaces | Make identification according to the spare parts catalog. Check the driven disk, pressure disk, replace if necessary |
Leakage of the working cylinder with release bearing | Replace slave cylinder with release bearing |
Clutch pulls, power unit vibrates | |
Air in the system, master or / and working cylinders are faulty | Replace defective part. Check the brake fluid level, bleed the system, check for leaks |
Interruptions in the engine | Check engine adjustment, make adjustments |
Clutch disc installed | Make identification according to the spare parts catalog |
Insufficiently rigid or broken implement support | Make identification according to the spare parts catalog |
The lining of the driven disk, the contact surfaces of the pressure plate and the flywheel are oiled (clutch oil leak) | Check and, if necessary, replace the seals on the transmission input shaft or on the crankshaft. Clean the driven plate, pressure plate and flywheel |
Misalignment, jamming of the release bearing on the guide sleeve (one-sided pressing on the disc spring of the pressure plate) | Replace release bearing and guide bush. Check drive elements and drive element supports |
Possible causes of malfunction | Remedy |
The contact surface of the pressure plate only comes off on one side due to misalignment of the release bearing. Warping of the pressure plate during installation. The contact surface of the pressure plate comes off on one side only | Check clutch lining surface on flywheel, pressure plate and cup spring, replace pressure plate if necessary. Replace release bearing and guide bush |
Too much grease on the input shaft (traces of grease on the driven disc, pressure plate and flywheel) | Clean the pressure plate and flywheel from grease, if damaged (traces of crushing, overheating, grooves) replace. Remove grease from hub and shaft, lightly lubricate shaft with grease. Move the driven disc to remove excess grease |
The slave cylinder with the release bearing is unevenly installed on the clutch housing | Check the threaded connection of the slave cylinder with the clutch housing |
Noises at idle | |
Vibration damper spring failure | Replace driven disk |
Driven disc has no damper (rattles at idle) | Install the clutch disc with damper |
Warping or breakage of the pressure plate, imbalance | Replace pressure plate |
Uneven engine operation | Check engine setting, correct if necessary |
Increased mutual displacement of the engine block / gearbox (no centering bushings) | Before installing the gearbox, insert the dowel sleeves |
Metal spacer rubbing against flywheel | Install the metal spacer on the sealing flange and push it onto the centering sleeves |
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