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CLUTCH 2A-5
Corrosion, rust, or burrs can be removed from splines
using an oilstone or fine-tooth file. Install driven plate
on clutch shaft. Driven plate must move freely on shaft.
(11) If components inspected in previous steps are in
good condition, proceed to next step. If one or more
problems were discovered during inspection procedure,
repair as necessary and proceed to next step.
(12) Check clutch housing alignment. Refer to Clutch
Housing Alignment. Correct alignment if necessary and
proceed to next step.
(13) Apply thin film of chassis grease to transmis-
sion clutch shaft splines. Do not apply grease to shaft
pilot hub.
(14) Install pilot bushing lubricating wick.
(15) Install transmission and clutch components. Re-
fer to Clutch Installation.
(16) Lower vehicle.
NOTE: Do not replace the throwout bearing unless ac-
tually defective. Refer to Clutch Area Noises.
Clutch Pedal Pulsation
Clutch pedal pulsation can be described as a rapid up-
and-down or pumping-type movement of the pedal that
is not accompanied by any noise. In most cases, pedal
movement is slight and cannot be observed but can be
felt by the driver. However, on occasion, pedal move-
ment will be great enough to be visually observed and
cause a noticeable vibration.
Clutch pedal pulsation occurs when the throwout
bearing makes initial contact with the clutch cover re-
lease levers (clutch partially disengaged), or at any time
the bearing is in contact with the release levers. Pulsa-
tion is usually caused by incorrect clutch release lever
height or clutch housing misalignment. Check clutch
operation as follows.
(1) Start engine, slowly depress clutch pedal until
throwout bearing makes initial contact with clutch re-
lease levers, and check for pulsation.
NOTE: Some minor pulsation is normal.
(2) Continue to depress clutch pedal while checking
for pulsation until pedal is fully depressed.
(3) If pulsation is not evident or is minor, stop re-
pair. If pulsation is very rapid and can be felt through-
out vehicle, refer to Clutch-Related Vibrations. If
vehicle displays pulsation symptoms, proceed to next
step.
(4) Remove transmission and clutch components.
Refer to Clutch Removal.
(5) Remove pilot bushing lubricating wick and soak
wick in engine oil.
(6) Inspect clutch cover release levers. If levers are
bent or excessively worn, replace clutch cover and pro-
ceed to step (8). If release levers are in good condition,
clean oil and dirt from clutch cover assembly using
mineral spirits, allow assembly to air dry and proceed to
next step.
(7) Sand clutch cover pressure plate surface lightly
using fine emery cloth.
: (8) Lubricate clutch cover release lever pivots
lightly with chassis grease.
NOTE: Apply lubricant to the pivots sparingly. Exces-
sive lubrication could result in grease contamination of
the driven plate and pressure plate surface.
(9) Check and adjust clutch cover release lever
height if necessary.
NOTE: If release lever height cannot be adjusted,
the
levers are bent and the cover must to be replaced.
(10) Check clutch housing alignment. Refer to Clutch
Housing Alignment. Correct alignment if necessary and
proceed to next step.
(11) Apply thin film of chassis grease to transmis-
sion clutch shaft splines but do not apply grease to shaft
pilot hub.
(12) Install pilot bushing lubricating wick.
(13) Install clutch components and transmission. Re-
fer to Clutch Installation.
Clutch Related f ibrations
Clutch related vibrations differ from pedal pulsations
in frequency and magnitude. They usually occur at rela-
tively high engine speeds (over 1500 rpm), are not af-
fected by clutch pedal position, and can be felt
throughout the vehicle.
Although clutch related vibrations are usually caused
by clutch component imbalance, this condition occurs
very infrequently because the clutch cover and driven
plate are balanced as a unit during assembly. At this
time, the cover and plate are installed on the crank-
shaft/flywheel assembly and given a final fine-tune bal-
ance before installation in the vehicle.
Replacement of clutch components to correct vibra-
tions should be performed only after exhausting all
other possibilities. Check clutch operation as follows.
(1) Raise vehicle on hoist and check engine front
support cushion interlocks for grounding. Repair as nec-
essary. Check other engine components (e.g., exhaust
manifold, valve cover, etc.) for grounding on body or
frame. If one of these components is grounded, repair
and check for vibration. If vibration ceases, stop repair.
If vibration continues, lower vehicle and proceed to next
step.
(2) Disconnect accessory drive belts one at a time,
start engine, and check for vibration. If vibration stops
after removal of a drive belt, cause of vibration is re-
lated to accessory driven by belt or by belt itself. Repair
as necessary. If vibration persists after checking all
belts and accessories, proceed to next step.
(3) Raise vehicle on hoist and remove transmission
and clutch housing. Refer to Clutch Removal.
(4) Support engine firmly.
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Troubleshooting
