Troubleshooting GuideOn the EXEDY Clutch Europe troubleshooting pages you will find solutions to any problems you may have experienced with your clutch. Select a link on the left depending on whether your problem lies with a cover, disc or bearing or view our good fitting practices. You can now also view a presentation to help you avoid buying imitation EXEDY parts.
Engine revving when power applied during acceleration / will not transmit power. Evidence of oil contamination on cover assembly.
Symptom :  Clutch cover pressure plate assembly contaminated with oil.
Cause :
Solution : 
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No clamp load onto clutch disc.
Symptom :
Cause :
Solution : 
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Worn clutch disc facing fibres that have become lodged between diaphragm spring and clutch cover housing causing loss of clamp load.
Symptom :
Cause :
Note: These problems are common on farm vehicles, vehicles travelling on sand and 4x4 recreational vehicles. Solution : 
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Hold down bolts still in pressure plate assembly.
Unable to adjust. Will not transmit power. Symptom :
Cause : Remove hold down bolts. Note: These problems are common on farm vehicles, vehicles travelling on sand and 4x4 recreational vehicles. Solution : 
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Worn clutch disc facing fibres and dirt that have become lodged between diaphragm spring and clutch cover housing causing loss of clamp load.
Symptom :
Cause :
Note: These problems are common on farm vehicles, vehicles travelling on sand and 4x4 recreational vehicles. Solution : 
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Excessive wear on diaphragm tips and a highly glazed pressure plate casting.
Symptom :
Cause :
Solution : 
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Clutch diaphragm fingers or levers are uneven.
Symptom :
Cause :
Solution : 
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No gear selection/difficult engagement. Stretched and damaged retractor clip (clip stretched above diaphragm).
Symptom : Over adjustment of clutch that has caused stretching of retractor clips on clutch cover pressure plate assembly. Cause :
Solution : 
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Burst pressure plate casting.
Symptom :
Cause : Always resurface flywheel before installing new clutch. Solution : 
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Unable to change gear/bent drive straps.
Symptom :
Cause :
Solution : 
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Excessively scored clutch cover pressure plate assembly.
Symptom : Clutch cover and clutch disk, being of different brands, rub against one another.
Cause :
Always use EXEDY matching cover and disc to ensure original equipment quality and compatibility.
Solution : 
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Warped clutch cover pressure plate assembly casting.
Symptom :
Only clutch disc was replaced which caused a vacuum not allowing the clutch disc to separate from the clutch cover pressure plate assembly casting when the clutch is in disengaged position.
Cause :
Always replace clutch disc, clutch cover pressure plate assembly and clutch thrust release bearing when replacing clutch system.
Solution : 
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Grinding gears/stretched and damaged retractor clip (clip under diaphragm).
Symptom :
Clutch cover pressure plate assembly has been dropped during installation or during transit causing damage to retractor clips.
Cause :
Always check components before fitting and ensure that the tip of the retractor clip is resting on top of the diaphragm. This can be checked by a feeler gauge. (This is the installer's responsibility).
Solution : 
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Diaphragm contacts clutch disc. Grinding in gear and unable to obtain clutch adjustment.
Symptom :
Cause :
Solution : 
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Bearing retainer clip not connected to diaphragm.
Symptom :
Cause : When the transmission is installed on the mating area of the engine, the release bearing is set into position where the release fork of the transmission is fitted. After the transmission is installed, the release lever must be pulled firmly in the direction opposite to the release. The bearing is then snapped in. Also refer to manufacturer's specifications. Solution : 
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Vehicle vibrates/shakes when clutch is being released when pulling away.
Dished and warped flywheel. Symptom :
Cause : Always resurface flywheel before installing new clutch. Solution : 
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Highly glazed to a mirror finish pressure plate cover assembly casting/red dust on clutch components.
Symptom :
Cause :
Solution : 
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Oily facings.
Symptom :
Cause :
Solution : 
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Melted grease on clutch disc side plate.
Symptom :
On this example the wrong grade of grease was used, affecting the co-efficiency of the disc material.
Cause : Use vehicle manufacturer's specified grade of grease. Must be high melting point grease. Solution : 
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Melted grease on clutch disc side plate.
Symptom :
Cause :
Solution : 
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Improper driving practice. Constantly shifting down gears.
Symptom :
Cause : Driver education. Solution : 
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Broken clutch facings flywheel side.
Symptom :
Cause :
Solution : 
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Premature wear sintered button type clutch disc.
Symptom : Bedding in procedure not observed for cerametallic buttons. Cause : Driver education - observe bedding in procedure. Due to the weight of this type of disc it takes longer for the rotating clutch to slow down while the clutch cover assembly is in a separation position away from the clutch disc. Clutch must be be pressed a few seconds longer while shifting gear, specifically when there is no clutch brake attached to the system. Solution : 
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Burst clutch disc/no transmitted power.
Symptom :
Cause :
Solution :
Difficult gear engagement/broken rubber dampeners.
Symptom :
Cause :
Solution : 
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Torsion dampener stopper springs thrown out of side plate/stop pins worn.
Symptom :
Cause :
Solution : 
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Grinding in all gears/damaged and burred splines.
Symptom : Defective pilot bearing or bushing. This causes angular wear of spline teeth, not allowing the clutch disc to slide on the spline teeth. It also causes the clutch disc to possibly stick on the flywheel or not separate from the clutch cover pressure plate assembly. This results in poor separation and no disengagement. Cause : Fit new pilot bearing or bushing. Solution : 
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Power not transmitting to drive train because of broken facings.
Symptom : Parts of the disc friction material are broken from rivet to rivet along with part of the cushioned segment. This is due to down shifting of gear (i.e. the speed of the vehicle at the rear wheels is travelling faster than the engine RPM when gear was down shifted). Cause : Driver education. Solution : 
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Damaged torsion springs.
Symptom : Springs deteriorate when engine torque is higher than clutch torque. This is due to the very different characteristics in the design of this particular clutch disc. Cause : Choose and fit appropriate EXEDY clutch to suit this application. Use silent type design. Solution : 
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Torque stopper springs broken. Difficult gear engagement which may lead to clutch failure.
Symptom :
Cause : Refer to 'Good Fitting Practices'. Solution : 
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No drive, power not transmitted because of broken segments on clutch disc.
Symptom : Cushion spring steel segents uniformly separated from hub area due to :
Cause :
Solution : 
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Clutch disc completely ruined.
Symptom : Clutch disc fitted incorrectly (i.e. back to front). Cause : Ensure disc is fitted correctly. Solution : 
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Damaged clutch facings.
Symptom : Disc has been dropped possibly during installation or in transit. Cause : Always check before installation that facing is intact. Solution : 
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Different number of spline on main drive to those on clutch disc/diameter of spline incorrect.
Symptom : Careless fitting practice. The right clutch disc was not checked on main drive spline before installation. Cause :
Solution : 
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Noisy and cannot transfer power / splines completely disintegrated.
Symptom :
Cause :
Solution : 
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Grinding noise in gearbox/non release.
Warped and bent clutch disc. Symptom :
Cause :
Solution : 
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Clutch disc side plate contacts inner diameter of casting.
No clutch adjustment (diaphragm over centre/clutch disc side plate interference). Symptom : Careless mechanical fitting practices. Cause : Always mate clutch disc to pressure plate casting and flywheel. Ensure no contact is made before installing new clutch. Solution : 
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Clutch drag leading to total clutch failure. Signs of red dust on clutch disc as seen in photo.
Symptom : Severe misalignment between mating surfaces of the bell housing and the rear of the motor. Cause :
Solution : 
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High pitched squeal. Excessively worn diaphragm spring.
Symptom : Clutch thrust bearing fitted incorrectly (i.e. back to front). Cause : Replace with new bearing fitted correctly (i.e. right way round). Solution : 
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High pitched squealing noise. Damaged bearing.
Symptom : Bearing fitted incorrectly. Cause : Fit bearing correctly. Ensure clutch cover pressure plate assembly has not been damaged from previous clutch thrust bearing. Solution : 
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Damaged clutch thrust bearing. Diaphragm spring excessively worn.
Symptom : The clutch has not been adjusted correctly since installation or has never been adjusted during any routine service. The clutch thrust bearing and the diaphragm of the clutch cover pressure plate assembly have worn indentations in each other. Cause :
Solution : 
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Broken saddle clip.
Symptom : Careless installation as spring retaining clip not connected to fork during installation or tension on wire retaining clip not correct. Cause :
Solution : 
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Excessive score marks on clutch thrust bearing.
Symptom : Clutch thrust bearing carrier incorrectly fitted to clutch release fork causing bearing carrier to spin off the fork tips and bearing carrier saddle. This is also caused if the tension on the release bearing carrier wire clip is not sufficient. Cause :
Solution : 
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Worn clutch thrust bearing carrier.
Symptom : Faulty installation as the clutch thrust bearing carrier is worn on the saddle where the fork pivots. This also reduces thre tension on the wear clip retainer. In this case, due to the lack of tension, the fork has become dislodged and scored the back of the bearing. Cause : Always replace worn clutch thrust bearing carriers and forks. Solution : 
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Advice :
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Sticky clutch pedal/pedal roughness.
Worn bearing slide. Symptom :
Cause : Always replace worn bearing slide/nose cone gearbox slide when installing new clutch. Solution : 
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Rattling from clutch area while idling, usually after new clutch is installed. Worn absorber rubber tip.
Symptom :
Cause :
Solution : 
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Power not transmitted in first gear when taking off or slipping for a few seconds at take off. Damaged or excessively worn dual mass flywheel.
Symptom : Worn or broken arc springs in dual mass flywheel. Cause :
Solution : 
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Worn fixed gearbox slide/gearbox nose cone slide not replaced.
Symptom : Worn bearing slide/gearbox cone slide not replaced. Cause : Renew or re-sleeve gearbox bearing slide. Solution : 
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Unable to select gear and unable to stop rotation of main drive shaft.
Symptom :
Cause :
Solution : 
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 In 1996 we moved to a new 3,000 m2 warehouse, enabling us to hold larger stock levels and improve our supply to the European Aftermarket. Throughout the 1990's we supplied the clutch that saw Ferrari to many Formula 1 Grand Prix victories. From the pedigree of this Formula 1 heritage, the EXEDY Racing Clutch Range was born.  |
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