Component Tests

Manual Transaxle and Clutch

Component Tests

Clutch Slippage

1. Chock the wheels.

2. Apply the parking brake.

3. Depress and release the clutch pedal slowly to check if the pedal is binding.
- If the clutch pedal is not binding, proceed to the next step of this procedure.

- If the clutch pedal is binding, inspect and repair as necessary. Test the system for normal operation. Proceed to the next step, if necessary.


4. Depress the clutch pedal.

5. Start the engine.

6. Shift the transmission to 4th gear.

7. Increase engine rpm to 2,000 and slowly release the clutch pedal. If the engine stalls within 5 seconds, the clutch is not slipping.
- If the clutch is slipping, remove the clutch disc and pressure plate. Inspect the clutch disc and pressure plate for wear or damage. Inspect the flywheel for glazing and damage. Check the clutch release hub and bearing for binding and inspect the guide tube. Inspect the input shaft for wear and damage. Repair all components as necessary.


Clutch Chatter or Shudder

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Inspect the engine and transmission mounts for looseness and damage.
- If the mounts are OK, proceed to the next step.

- If the mounts are loose or damaged, tighten or install new mounts as necessary. Test the system for normal operation.


3. Check for loose bolts that retain the clutch pressure plate to the flywheel.
- If the bolts are tightened to specification proceed to the next step.

- If the bolts are loose, tighten the bolts to specification. Test the system for normal operation.


4. Remove the clutch disc and pressure plate. Inspect the clutch disc and pressure plate for wear and damage, and check the clutch disc runout. Refer to Clutch Disc Check . Inspect the flywheel for glazing and damage. Refer to Flywheel Runout Check . Inspect the input shaft for wear, damage and eccentricity. Repair all components as necessary.

Clutch Drag

1. Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
- If the fluid level is correct, proceed to the next step.

- If the fluid level is low, add fluid as necessary. Inspect the clutch hydraulic system for leaks and repair as necessary. Test the system for normal operation.


2. Depress and release the clutch pedal to check for a spongy pedal.
- If the pedal feels OK, proceed to the next step.

- If the pedal feels spongy, bleed the clutch hydraulic system. Refer to Clutch System Bleeding . Test the system for normal operation.


3. Remove the clutch disc and pressure plate. Inspect the clutch disc and pressure plate for wear and damage, and check the clutch disc runout. Refer to Clutch Disc Check . Repair all components as necessary.

Hard Shifting

1. Verify that the clutch hydraulic fluid reservoir is filled to the correct level.
- If the fluid level is correct, proceed to the next step.

- If the fluid level is low, add fluid as necessary. Check the clutch baldric system for leaks, and repair as necessary. Test the system for normal operation.


2. Depress and release the clutch pedal to check for a spongy pedal.
- If the pedal feels OK, proceed to the next step.

- If the pedal feel spongy, bleed the clutch hydraulic system. Refer to Clutch System Bleeding . Test the system for normal operation.


3. Remove the clutch disc and pressure plate. Inspect the clutch disc and pressure plate for wear or damage. Refer to Clutch Disc Check . Check the clutch release hub and bearing for binding and inspect the guide tube. Inspect the input shaft for wear and damage. If all of the components are OK, proceed to the next step. Otherwise, repair all components as necessary. Test the system for normal operation.

4. Inspect the transmission housing, shafts, forks and synchronizer assemblies. Repair all components as necessary.