Possible clutch malfunctions, their causes and solutions (Focus 2)

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Cause of malfunctionMethod of elimination
Incomplete disengagement of the clutch (clutch "leads*")
Reduced full travel of clutch pedalAdjust the clutch drive
Warpage of the driven disk (end runout more than 0.5 mm)Straighten the disc or suede it with a new one
Irregularities on the surfaces of the friction linings of the driven diskReplace the linings or the driven disc assembly
Loose rivets or broken friction linings of the driven diskReplace the linings, check the disc axial runout
Seizure of the driven disk hub on the splines of the gearbox input shaftClean the splines, coat with LSC-15 grease. If the cause of the jamming is the crushing or wear of the splines, then replace the primary shaft or driven disk
Air in the hydraulic drive systemPump up the system
Fluid leaking from the hydraulic system through connections or damaged lines Fluid leaking from the master cylinder or slave cylinder of the clutch driveTighten the connections, replace damaged parts. Bleed the hydraulic drive system. Replace the master or slave cylinder
Loosening the rivets securing the pressure springReplace the clutch housing with pressure plate assembly
Misalignment or warping of the pressure plateSame
Incomplete clutch engagement (clutch slips)
No free play in the clutch pedalAdjust the clutch drive
Increased wear or burning of the friction linings of the driven diskReplace the friction linings or the driven disc assembly
Oiling of the friction linings of the driven disk, flywheel surfaces and pressure plateThoroughly wash the oily surfaces with white spirit, eliminate the causes of oily discs
Damage or seizure of the clutch driveTroubleshoot the problem causing the jamming
Jerks when engaging the clutch
The driven disk hub is jammed on the splines of the primary shaftClean the splines, lubricate with LSC-15 grease. If the cause of the jamming is the crushing or wear of the splines, then replace the primary shaft or driven disk if necessary
Oiling of the friction linings of the driven disk, flywheel surfaces and pressure plateThoroughly wash the oily surfaces with white spirit and eliminate the cause of the oily discs
Clutch drive mechanism jammingReplace deformed parts. Eliminate the causes of jamming
Increased wear of the friction linings of the driven diskReplace the pads with new ones, check for damage to the disc surface
Loosening the rivets of the friction linings of the driven diskReplace faulty rivets and, if necessary, linings
Damage to the surface or warping of the pressure plateReplace the clutch housing with pressure plate assembly
Increased noise when disengaging the clutch
Clutch release bearing worn, damaged or leaking greaseReplace the bearing
Increased noise when engaging the clutch
Breakdown or loss of elasticity of the driven disk damper springsReplace the slave disk assembly
Breakage, loss of elasticity or jumping off of the clutch release fork retaining springReplace the clutch release fork
Breakage of the plates connecting the pressure plate to the casingReplace the clutch housing with pressure plate assembly


(The original version can be found on the website: Fordbook.ru)






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