Pinpoint clutch tests

A1: CHECK CLUTCH SLIPPER.

1Block the wheels and apply the parking brake.

2Enter the START position.

3Start the engine and engage fourth gear. Keep the clutch pedal depressed.

4Let the engine run at approximately 2000 rpm.

5Slowly release the clutch pedal and try to maintain the engine crankshaft speed while releasing the pedal.

• Does the engine stall when the clutch pedal is fully released?

→ Yes

The clutch is fine.

→ No

Go to A1

A2: CHECK CLUTCH PEDAL PLAY.

1Manually apply the clutch pedal to the point where you feel resistance and release the pedal.

2Measure the pedal play.

• Is the measured play approximately (1 - 3) mm?

→ Yes

Go to A3

→ No

Go to B3

A3: CHECK THE CLUTCH PEDAL.

1Check the lubrication.

• Is the clutch pedal axle sufficiently lubricated?

→ Yes

Go to B3

→ No

Lubricate the clutch pedal shaft with high temperature grease (ESD-M1C220-A).

A4: CHECK CLUTCH PEDAL TRAVEL.

1Manually apply and release the clutch pedal.

2Measure the pedal stroke.

• Is the measured stroke approximately 133±3 mm?

→ Yes

Go to B3

→ No

Replace the clutch pedal.

B1: CHECK FOR CLUTCH JERKING.

1Enter the START position.

2Start the engine and engage first gear. Keep the clutch pedal depressed.

3Allow the engine to run at a crankshaft speed between 1200 rpm and 1500 rpm.

4Slowly release the clutch pedal.

• Does the car jerk when starting off?

→ Yes

Go to B2

→ No

The clutch is fine.

B2: CHECK ENGINE AND GEARBOX MOUNTS.

1Check the engine and transmission mounts for damage or loose bolts.

• Are the bolts loose or the engine and transmission mounts damaged?

→ Yes

If necessary, replace damaged engine mounts and/or tighten bolts.

→ No

Go to B3

B3: CHECK THE CLUTCH PRESSURE PLATE.

1Remove the clutch pressure plate.

- For additional information, refer to Section 308-01A/308-01B/308-01C.

- For additional information, refer to Section 308-01A/308-01B/308-01C.

• Does the clutch pressure plate show signs of wear or damage?

→ Yes

Replace the clutch pressure plate.

→ No

Go to B4

B4: CHECK CLUTCH FRICTION DISC.

1Visually inspect the clutch friction disc.

• Is the clutch friction disc worn (thickness: iB5 - less than 6.5 mm); MTX (less than xx mm), is it contaminated with oil, has burn marks or visible cracks in the friction material?

→ Yes

Replace the clutch friction disc.

→ No

Check the flywheel. For more information, refer to Cleaning and Inspecting the Flywheel in this section..

C1: CHECK BRAKE FLUID LEVEL.

1Check the brake fluid level.

• Is the brake fluid level in the reservoir between the MAX and MIN marks?

→ Yes

Go to C2

→ No

Top up the brake fluid, check the brake system and clutch system for leaks.

C2: CHECK CLUTCH PEDAL TRAVEL.

1Manually depress the clutch pedal and release it.

2Measure the pedal stroke.

• Is the measured stroke (133±3) mm?

→ Yes

Go to C3

→ No

Replace the pedal.

C3: CHECK DIAPHRAGM SPRINGS.

1Remove the gearbox.

- For additional information, refer to Section 308-03A/308-03B/308-03C.

- For additional information, refer to Section 308-03A/308-03B/308-03C.

• Do the clutch pressure plate and diaphragm spring show signs of wear or damage?

→ Yes

Replace the clutch pressure plate.

→ No

Go to B4

D1: CHECK THE CLUTCH PEDAL.

1Remove the gearbox.

- For additional information, refer to Section 308-03A/308-03B/308-03C.

- For additional information, refer to Section 308-03A/308-03B/308-03C.

• Do the clutch pressure plate and diaphragm spring show signs of wear or damage?

→ Yes

Replace the clutch pressure plate.

→ No

Check the crankshaft end play. Refer to Section 303-00 for additional information.

E1: CHECK THE NEUTRAL POSITION OF THE GEARBOX.

1Enter the START position.

2Depress the clutch pedal fully.

• Are there any noises when the clutch is engaged?

→ Yes

Go to E2

→ No

Gearbox problems. For more information, refer to Manual Gearbox iB5/MTX 75 available in this section..

E2: CHECK CLUTCH PEDAL PLAY.

1Measure the pedal play.

• Is the measured play approximately (1 - 3) mm?

→ Yes

Go to E3

→ No

Go to B3

E3: CHECK CLUTCH SLAVE CYLINDER WITH CLUTCH RELEASE BEARING.

1Remove the gearbox.

- For additional information, refer to Section 308-03A/308-03B/308-03C.

- For additional information, refer to Section 308-03A/308-03B/308-03C.

2Check the clutch slave cylinder bolts.

3Check the clutch release bearing for wear or corrosion.

• Are bolts loose or show signs of wear or rust?

→ Yes

Tighten the bolts and/or replace the clutch slave cylinder with the release bearing.

→ No

Go to E4

E4: CHECK CLUTCH FRICTION DISC TORSION SPRINGS.

1Check the torsion springs for wear.

• Do the torsion springs show signs of wear?

→ Yes

Replace the clutch friction disc.

→ No

Check the crankshaft end play. Refer to Section 303-00 for additional information.

F1: CHECK CLUTCH MASTER CYLINDER.

1Check the clutch master cylinder for leaks.

• Is the clutch master cylinder OK?

→ Yes

Go to F3

→ No

Replace the clutch master cylinder.

F2: CHECK CLUTCH HYDRAULIC LINES.

1Check hydraulic lines for loose connections and damage.

• Are the hydraulic lines in good condition?

→ Yes

Check the validity of the customer's complaint.

→ No

Replace hydraulic lines.

F3: CHECK CLUTCH SLAVE CYLINDER.

1Remove the transmission. For additional information, refer to Section 308-03A / 308-03B / 308-03C. or Check the clutch slave cylinder for leaks.

• Is the clutch slave cylinder OK?

→ Yes

Go to F2

→ No

Replace the clutch slave cylinder together with the clutch release bearing.