Dodge ZB 2005 - Page 188

CONDITION POSSIBLE CAUSES CORRECTION
Clutch disc facing burnt. Flywheel
and pressure plate surfaces glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace disc
and pressure plate.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
2. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc.
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Pressure plate diaphragm spring
bent or warped.
4. Replace pressure plate.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
ZB CLUTCH 6 - 5
CLUTCH (Continued)