Pinpoint clutch tests

A1: CHECK CLUTCH SLIP.

1 Block the wheels and apply the parking brake.

2 Drive the START position.

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

4 Run the engine at approximately 2000 rpm.

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

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

→ Yes

The clutch is ok.

→ No

Go to A1

A2: CHECK CLUTCH PEDAL PLAY.

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

2 Measure pedal play.

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

→ Yes

Go to A3

→ No

Go to B3

A3: INSPECT CLUTCH PEDAL.

1 Check lubrication.

• Is the clutch pedal shaft sufficiently lubricated?

→ Yes

Go to B3

→ No

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

A4: CHECK CLUTCH PEDAL STROKE.

1 Manually operate the clutch pedal and release it.

2 Measure the pedal travel.

• Is the measured stroke approximately 133±3 mm?

→ Yes

Go to B3

→ No

Replace clutch pedal.

B1: CHECK FOR JERKING CLUTCH.

1 Drive the START position.

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

3 Run the engine between 1200 rpm and 1500 rpm.

4 Slowly release the clutch pedal.

• Does the vehicle jerk when pulling away?

→ Yes

Navigate to B2

→ No

The clutch is ok.

B2: CHECK ENGINE AND GEARBOX MOUNTS.

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

• Are bolts loose or engine and transmission mounts damaged?

→ Yes

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

→ No

Go to B3

B3: INSPECT CLUTCH PRESSURE PLATE.

1 Remove the clutch pressure plate.

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

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

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

→ Yes

Replace clutch pressure plate.

→ No

Go to B4

B4: INSPECT CLUTCH FRICTION PLATE.

1 Visually inspect the clutch friction disc.

• Whether the clutch friction disc is worn (thickness: iB5 - less than 6.5mm; MTX - less than xx mm), is it oiled, does it have burn marks or visible cracks in the friction material?

→ Yes

Replace clutch friction disc.

→ No

Check the flywheel. For more information, refer to Cleaning and verification available in this section..

C1: CHECK BRAKE FLUID LEVEL.

1 Check the brake fluid level.

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

→ Yes

Go to C2

→ No

Add brake fluid, check the brake system and clutch system for leaks.

C2: CHECK CLUTCH PEDAL STROKE.

1 Manually depress the clutch pedal and release it.

2 Measure the pedal travel.

• Does the measured stroke amount to (133 ± 3) mm?

→ Yes

Go to C3

→ No

Replace pedal.

C3: CHECK DIAPHRAGM SPRINGS.

1 Remove the gearbox.

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

- For more information, please 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 clutch pressure plate.

→ No

Go to B4

D1: INSPECT CLUTCH PEDAL.

1 Remove the gearbox.

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

- For more information, please 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 clutch pressure plate.

→ No

Check crankshaft end play. See Section 303-00 for more information.

E1: CHECK GEARBOX NEUTRAL.

1 Drive the START position.

2 Fully depress the clutch pedal.

• Are there noises when the clutch is engaged?

→ Yes

Go to E2

→ No

Problems in the gearbox. For more information, refer to iB5/MTX 75 Manual Transmission available in this section..

E2: CHECK CLUTCH PEDAL PLAY.

1 Measure pedal play.

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

→ Yes

Go to E3

→ No

Go to B3

E3: INSPECT CLUTCH SLOPE TOGETHER WITH CLUTCH RELEASE BEARING.

1 Remove the gearbox.

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

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

2 Check the clutch slave cylinder bolts.

3 Check the clutch release bearing for wear or corrosion.

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

→ Yes

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

→ No

Go to E4

E4: INSPECT CLUTCH FRICTION PLATE TORSION SPRINGS.

1 Check torsion springs for wear.

• Do the torsion springs show signs of wear?

→ Yes

Replace clutch friction disc.

→ No

Check crankshaft end play. See Section 303-00 for more information.

F1: INSPECT CLUTCH MASTER CYLINDER.

1 Check clutch master cylinder for leaks.

• Is the clutch master cylinder OK?

→ Yes

Go to F3

→ No

Replace clutch master cylinder.

F2: INSPECT CLUTCH PIPING.

1 Check hydraulic lines for loose connections and damage.

• Are the hydraulic lines in order?

→ Yes

Check the validity of the customer's complaint.

→ No

Replace hydraulic lines.

F3: INSPECT CLUTCH SLOPE.

1 Remove the gearbox. See Section 308-03A / 308-03B / 308-03C for more information. 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.