POWERTRAIN

CLUTCH TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.

BASIC CLUTCH TROUBLE SHOOTING CHART

CONDITION POSSIBLE CAUSE CORRECTION

Chattering or Incorrect clutch adjustment Adjust clutch

Grabbing

Oil, grease or glaze on Disassemble and clean

facings or replace

Loose "U" joint flange See DRIVE AXLES

article

Worn input shaft spline Replace input shaft

Binding pressure plate Replace pressure plate

Binding release lever See CLUTCH article

Binding clutch disc hub Replace clutch disc

Unequal pressure plate Replace worn/misaligned

contact components

Loose/bent clutch disc Replace clutch disc

Incorrect transmission Realign transmission
alignment

Worn pressure plate, disc Replace damaged

or flywheel components

Broken or weak pressure Replace pressure

springs plate

Sticking clutch pedal Lubricate clutch pedal

& linkage

Incorrect clutch disc Replace clutch disc
facing

Engine loose in chassis Tighten all mounting

bolts

Failure to Oil or grease on clutch Clean or replace clutch

Release facings clutch disc

Incorrect release lever or See CLUTCH article
pedal adjustment

Worn or broken clutch Replace clutch disc
facings

Bent clutch disc or Replace damaged

pressure plate components

Clutch disc hub binding on Clean or replace clutch

input shaft disc and/or input shaft

Binding pilot bearing Replace pilot bearing

Sticking release bearing Replace release bearing

sleeve and/or sleeve

Binding clutch cable See CLUTCH article

Defective clutch master Replace master cylinder

Defective clutch slave Replace slave cylinder

Air in hydraulic system Bleed hydraulic system

Rattling Weak or broken release Replace spring and

lever spring check alignment

Damaged pressure plate Replace pressure plate

Broken clutch return spring Replace return spring

Worn splines on clutch disc Replace clutch disc

or input shaft and/or input shaft

Worn clutch release bearing Replace release bearing

Dry or worn pilot bearing Lubricate or replace

pilot bearing

Unequal release lever Align or replace

contact release lever

Incorrect pedal free play Adjust free play

Warped or damaged clutch Replace damaged

disc components

Slipping Pressure springs worn or Release pressure plate

Oily, greasy or worn Clean or replace clutch

facings disc

Incorrect clutch alignment Realign clutch assembly

Warped clutch disc or Replace damaged

pressure plate components

Binding release levers or Lubricate and/or

clutch pedal replace release

components


Squeaking Worn or damaged release Replace release bearing

Dry or worn pilot or Lubricate or replace

release bearing assembly

Pilot bearing turning in Replace pilot bearing

crankshaft and/or crankshaft

Worn input shaft bearing Replace bearing and

seal

Incorrect transmission Realign transmission
alignment

Dry release fork between Lubricate release fork

pivot and pivot


Heavy and/or Sticking release bearing Replace release bearing

Stiff Pedal sleeve and/or sleeve

Dry or binding clutch Lubricate and align
pedal hub components

Floor mat interference Lay mat flat in proper
with pedal area

Dry or binding ball/fork Lubricate and align
pivots components

Faulty clutch cable Replace clutch cable

Noisy Clutch Faulty interlock switch Replace interlock
Pedal switch

Self-adjuster ratchet Lubricate or replace
noise self-adjuster

Speed control interlock Lubricate or replace
switch interlock switch

Clutch Pedal Binding clutch cable See CLUTCH article Sticks Down

Springs weak in pressure Replace pressure plate plate

Binding in clutch linkage Lubricate and free

linkage


Noisy Dry release bearing Lubricate or replace

release bearing

Dry or worn pilot bearing Lubricate or replace

bearing

Worn input shaft bearing Replace bearing


Transmission Weak springs in pressure Replace pressure plate
Click plate

Release fork loose on ball Replace release fork
stud and/or ball stud

Oil on clutch disc damper Replace clutch disc

Broken spring in slave Replace slave cylinder cylinder

DRIVE AXLE - NOISE DIAGNOSIS

Unrelated Noises

Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. Ensure cause of trouble actually is in the drive axle before adjusting, repairing, or replacing any of its parts.

Non-Drive Axle Noises

A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most common noises are exhaust, tires, CV/universal joints and wheel trim rings.

In certain conditions, the pitch of the exhaust gases may sound like gear whine. At other times, it may be mistaken for a wheel bearing rumble.

Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also, some non-standard tires with an unusual tread construction may emit a roar or whine.

Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly diagnosed as drive axle problems.

Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are causing the noise before disassembling the drive axle.

Gear Noise

A "howling" or "whining" noise from the ring and pinion gear can be caused by an improper gear pattern, gear damage, or improper bearing preload. It can occur at various speeds and driving conditions, or it can be continuous.

Before disassembling axle to diagnose and correct gear noise, make sure that tires, exhaust, and vehicle trim have been checked as possible causes.

Chuckle

This is a particular rattling noise that sounds like a stick against the spokes of a spinning bicycle wheel. It occurs while decelerating from 40 MPH and usually can be heard until vehicle comes to a complete stop. The frequency varies with the speed of the vehicle.

A chuckle that occurs on the driving phase is usually caused by excessive clearance due to differential gear wear, or by a damaged tooth on the coast side of the pinion or ring gear. Even a very small tooth nick or a ridge on the edge of a gear tooth is enough the cause the noise.

This condition can be corrected simply by cleaning the gear tooth nick or ridge with a small grinding wheel. If either gear is damaged or scored badly, the gear set must be replaced. If metal has broken loose, the carrier and housing must be cleaned to remove particles that could cause damage.

Knock

This is very similar to a chuckle, though it may be louder, and occur on acceleration or deceleration. Knock can be caused by a gear tooth that is damaged on the drive side of the ring and pinion gears. Ring gear bolts that are hitting the carrier casting can cause knock. Knock can also be due to excessive end play in the axle shafts.

Clunk

Clunk is a metallic noise heard when an automatic

transmission is engaged in Reverse or Drive, or when throttle is applied or released. It is caused by backlash somewhere in the driveline, but not necessarily in the axle. To determine whether driveline clunk is caused by the axle, check the total axle backlash as follows:

  1. Raise vehicle on a frame or twinpost hoist so that drive
    wheels are free. Clamp a bar between axle companion flange and a part
    of the frame or body so that flange cannot move.

  2. On conventional drive axles, lock the left wheel to keep
    it from turning. On all models, turn the right wheel slowly until it
    is felt to be in Drive condition. Hold a chalk marker on side of tire
    about 12" from center of wheel. Turn wheel in the opposite direction
    until it is again felt to be in Drive condition.

  3. Measure the length of the chalk mark, which is the total

axle backlash. If backlash is one inch or less, drive axle is not the source of clunk noise.

Bearing Whine

Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by malfunctioning pinion bearings. Pinion bearings operate at drive shaft speed. Roller wheel bearings may whine in a similar manner if they run completely dry of lubricant. Bearing noise will occur at all driving speeds. This distinguishes it from gear whine, which usually comes and goes as speed changes.

Bearing Rumble

Bearing rumble sounds like marbles being tumbled. It is usually caused by a malfunctioning wheel bearing. The lower pitch is because the wheel bearing turns at only about 1/3 of drive shaft speed.

Chatter On Turns

This is a condition where the entire front or rear of vehicle vibrates when vehicle is moving. The vibration is plainly felt as well as heard. Extra differential thrust washers installed during axle repair can cause a condition of partial lock-up that creates this chatter.

Axle Shaft Noise

Axle shaft noise is similar to gear noise and pinion bearing whine. Axle shaft bearing noise will normally distinguish itself from gear noise by occurring in all driving modes (Drive, cruise, coast and float), and will persist with transmission in Neutral while vehicle is moving at problem speed.

If vehicle displays this noise condition, remove suspect axle shafts, replace wheel seals and install a new set of bearings. Re-evaluate vehicle for noise before removing any internal components.

Vibration

Vibration is a high-frequency trembling, shaking or grinding condition (felt or heard) that may be constant or variable in level and can occur during the total operating speed range of the vehicle.

The types of vibrations that can be felt in the vehicle can be divided into 3 main groups:

  1. Vibrations of various unbalanced rotating parts of the
    vehicle.

  2. Resonance vibrations of the body and frame structures caused
    by rotating of unbalanced parts.

  3. Tip-in moans of resonance vibrations from stressed engine or
    exhaust system mounts or driveline flexing modes.

DRIVE AXLE - RWD TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle configuration. The purpose of this Trouble Shooting information is to provide a list of common causes to problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing. For definitions of listed noises or sounds, see DRIVE AXLE - NOISE DIAGNOSIS under POWERTRAIN.

DRIVE AXLE (RWD) TROUBLE SHOOTING

CONDITION POSSIBLE CAUSE CORRECTION

Knocking or Clunking

Differential Side Gear

Clearance Check Clearance

Worn Pinion Shaft Replace Pinion Shaft

Axle Shaft End Play Check End Play

Missing Gear Teeth Check Differential/

Replace Gear

Wrong Axle Backlash Check Backlash

Misaligned Driveline Realign Driveline

Clinking During Engagement

Side Gear Clearance Check Clearance

Ring and Pinion Backlash Check Backlash

Worn/Loose Pinion Shaft Replace Shaft/Bearing

Bad "U" Joint Replace "U" Joint

Sticking Slip Yoke Lube Slip Yoke

Broken Rear Axle Mount Replace Mount

Loose Drive Shaft Flange Check Flange

Click/Chatter On Turns

Differential Side Gear

Clearance Check Clearance

Wrong Turn On Plates (1) Replace Clutch Plates

Wrong Differential

Lubricant (1) Change Lubricant


Knock Or Click Flat Spot on Rear

Wheel Bearing Replace Wheel Bearing


Low Vibration At All Speeds

Faulty Wheel Bearing Replace Wheel Bearing

Faulty "U" Joint Replace "U" Joint

Faulty Drive Shaft Balance Drive Shaft

Faulty Companion Flange Replace Flange

Faulty Slip Yoke Flange Replace Flange
(1) - Limited slip differential only.

FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING

NOTE: This is GENERAL information. This article is not intended

to be specific to any unique situation or individual vehicle

configuration. The purpose of this Trouble Shooting

information is to provide a list of common causes to

problem symptoms. For model-specific Trouble Shooting, refer to SUBJECT, DIAGNOSTIC, or TESTING articles available in the section(s) you are accessing.

BASIC FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING CHART
CONDITION POSSIBLE CAUSE

Grease Leaks CV boot torn or cracked

Clicking Noise on Cornering Damaged outer CV Clunk Noise on Acceleration Damaged inner CV

Vibration or Shudder Sticking, damaged or worn CV

on Acceleration Misalignment or spring height