CLUTCH SERVICE SAFETY PRECAUTIONS
When servicing the clutch, exercise the following precautions.
- Always wear eye protection when working underneath a vehicle.
- Remove asbestos dust only with a special, approved vacuum collection
system or an approved liquid cleaning system.
- Never use compressed air or a brush to clean off asbestos dust.
- Follow all federal, state, and local laws when disposing of collected
asbestos dust or liquid containing asbestos dust.
- Never work under a vehicle that is not raised on a hoist or supported
by safety or jack stands.
- Use jack stands and special jacks to support the engine and
- Have a helper assist in removing the transmission.
- Be sure the work area is properly ventilated, or attach a ventilating
hose to the vehicle's exhaust system when an engine is to be run
- Do not allow anyone to stand in front of or behind the automobile
while the engine is running.
- Set the emergency brake securely and place the gearshift in neutral
when running the engine of a stationary vehicle.
- Avoid touching hot engine and exhaust system parts. Whenever possible,
let the vehicle cool down before beginning to work on it.
Clutch Linkage Adjustment
Except for systems with self-adjusting mechanisms, the release bearing
should not touch the pressure plate release levers when the clutch is
engaged (pedal up). Clearance between these parts prevents permature
clutch plate, pressure plate, and release bearing wear. As the clutch
disc wears and becomes thinner, this clearance changes.
Clearance can be ensured by adjusting the clutch linkage so the pedal
has a specified amount of play, of free travel. Free travel is the
distance a clutch pedal moves when depressed, before the clutch fork
begins to move the release bearing.
To check pedal play, use a tape measure or ruler. Place the tape measure
or ruler beside the clutch pedal and the end against the floor of the
vehicle and note the reading. Then, depress the clutch pedal just enough
to take up the pedal play and note the reading again. The difference
between the two readings is the amount of pedal play.
Adjustment should be performed when pedal play is not correct or when
the clutch does not engage or disengage properly. To adjust clutch pedal
play, refer to the manufacturer's service manual for the correct
procedure and adjustment point locations. Often pedal play can be
increased or decreased by turning a threaded fastener located either
under the dash at the clutch pedal or where the linkage attaches to the
Clean the linkage with a shop towel and solvent, if necessary, before
checking it and replacing any damaged or missing parts or cables. Check
hydraulic linkage systems for leaks at the clutch master cylinder,
hydraulic hose, and slave cylinder. Then, adjust the linkage to provide
the manufacturer's specified clutch pedal play.
External Clutch Linkage Lubrication
External clutch linkage should be lubricated at regular intervals, such
as during a chassis lubrication. Refer to the vehicle's service manual
to determine the proper lubricant. Many clutch linkages use the same
chassis grease that is used for suspension parts and U-joints. Lubricate
all the sliding surfaces and pivot points in the clutch linkage. The
linkage should move freely after lubrication.
On Vehicles with hydraulic clutch linkage, check the clutch master
cylinder reservoir fluid level. It should be approximately 1/4 inch from
the top of the reservoir. If it must be refilled, use approved brake
fluid. Also, since the clutch master cylinder does not consume fluid,
check for leaks in the master cylinder, connecting flexible line, and
slave cylinder, if the fluid is low.