Repair Manual MAN-00190
THAR CRDe BS-IV MAY 2012/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.
Clutch cover & Disc runout –
A warped cover or diaphragm spring will result in clutch grab and / or incomplete release of clutch
plate.
If the clutch alignment tool is not used then the misalignment of the clutch plate can cause distortion
of the cover and also disc damage.
The cover can also get misaligned due to improper tightening of the cover onto the flywheel. The only
way to avoid is that the bolts must be tightened alternatively (diagonal pattern) and evenly i.e. 2 to 3
thread a time only.
A noisy gearshift operation especially the 1
st
and 2
nd
gear can be due to clutch not getting disengaged
completely. To check it, jack up the rear axle. Lift the axle till both the wheels are rotating freely.
Press the clutch pedal completely and start the engine, the wheels should not be spinning. Now slowly
release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If some
spinning is noticed then it indicates improper lift of the pressure plate. First check the bleeding and
the pedal travel then check for the pressure plate lift.
Clutch Housing Misalignment –
The clutch housing has to be aligned with the engine so that the input shaft is aligned with the
crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It
can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also
damage the spline of the input shaft and clutch hub’s well as the clutch splines
Normally the clutch housing misalignment is a result of:
Incorrect seating on the engine/transmission.
Missing alignment dowel holes.
Loose or missing mounting bolt.
Mounting surfaces that are damaged/ not parallel.
To check the clutch housing misalignment bell housing runout will also need to be checked.
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