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:
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.
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.
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:
Vibrations
of various unbalanced rotating parts of the
vehicle.
Resonance
vibrations of the body and frame structures caused
by rotating of
unbalanced parts.
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
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