Clutch Troubleshooting - Toyota Hilux Surf 1993 Owner's Manual

CL–2
Problem
Hard to shift or will
not shift
Transmission jumps
out of gear
Clutch slips
Clutch grabs/
chatters
Clutch pedal spongy
Clutch noisy
TROUBLESHOOTING
Possible cause
Clutch pedal freeplay excessive
Air in clutch lines
Clutch release cylinder faulty
Clutch master cylinder faulty
Clutch disc out of true, runout is exces–
sive or lining broken
Splines on input shaft or clutch disc dirty
or burred
Clutch pressure plate faulty
Clutch pilot bearing worn
Clutch pedal freeplay insufficient
Clutch disc lining oily or worn out
Pressure plate faulty
Release fork binding
Clutch disc lining oily or worn out
Pressure plate faulty
Clutch diaphragm spring bent
Engine mounts loose
Air in clutch lines
Clutch release cylinder faulty
Clutch master cylinder faulty
Loose part inside housing
Release bearing worn or dirty
Pilot bearing worn
Release fork or linkage sticking
CLUTCH – Troubleshooting
Adjust pedal freeplay
Bleed clutch system
Repair release cylinder
Repair master cylinder
Inspect clutch disc
Repair as necessary
Replace clutch cover
Replace pilot bearing
Adjust pedal freeplay
Inspect clutch disc
Replace clutch cover
Inspect release fork
Inspect clutch disc
Replace clutch cover
Align clutch diaphragm
Repair as necessary
Bleed clutch system
Repair release cylinder
Repair master cylinder
Repair as necessary
Replace release bearing
Replace pilot bearing
Repair as necessary
Remedy
CL–3
CL–4
CL–10
CL–7
CL–13
CL–12
CL–14
CL–14
CL–3
CL–13
CL–14
CL–13
CL–14
CL–15
CL–4
CL–10
CL–7
CL–15
CL–14
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