3.2.4 Disassemble View
3.2.4.1 Disassemble View

Clutch

7

8 9

13

12

1

3

15

14

14

2

2

5

4

6

10

11

FE03-2021b

Legend

1. Master Cylinder Oil Outlet Components
2. Clutch Master Cylinder Retaining Nuts
3. Pin φ8 × 24
4. Lock Pin
5. Clutch Master Cylinder Assembly
6. Clutch Pedal and Brake Pedal Bolts
7. Clutch Pedal Return Spring
8. Clutch Pedal
9. Lubrication Sleeve

10. Pedal Retaining Nut
11. Clutch Pedal and Brake Pedal Bracket Mounting Nut
12. Clutch Pedal and Brake Pedal Bracket Mounting Bolt
13. Clutch Pedal Bracket
14. Screw Driving Double Steel Wire Hoop
15. Master Cylinder Oil Inlet Hose

Transmission / Drive Axle

Clutch System

3-7

Clutch Body

3

2

1

4

7

6

8

5

9

11

10

FE03-2022b

Legend

1. Clutch Driven Plate
2. Clutch Pressure Plate
3. Release Bearings
4. Transmission Assembly
5. Separation Fork
6. Clutch Cylinder
7. Clutch Cylinder Bolts

8. Separation Fork Jacket
9. Clutch Hydraulic Hose
10. Clutch Cylinder Oil Inlet Pipe
11. Clutch Hydraulic Hose Retaining Bracket

3-8

Clutch System

Transmission / Drive Axle

3.2.5 Diagnostic Information and Procedures
3.2.5.1 Diagnosis Description

Refer to "Description and Operation" and start system diagnostics. When a malfunction occurs. Refer to "Description and Operation
" as it will help determine the correct symptom diagnostic procedures, so that it will also help to determine whether the customer
described condition is normal. Refer to

3.2.2

 

Description and Operation

to confirm the correct procedures for system diagnostics.

3.2.5.2 Clutch Inseparable Malfunction (Gearshift Lever Can Not Select Gear)

Fault Definition: In the normal engine running condition, press the clutch pedal to the full travel, the gearshift lever can
not engage to or disengage from a gear.

Step 1

check whether there are obstacles under the clutch pedal?

(a)

Check whether the floor blocks the clutch pedal travel.

(b)

Check whether installed after market equipment, such as
rubber flooring, etc. affecting the clutch pedal travel.

Yes

Repair the faulty part.

No

Step 2

Press the clutch pedal, check whether the clutch release fork moves?

Yes

Go to step 8

No

Step 3

Check whether the travel between the clutch pedal and clutch master cylinder is too great?

(a)

Check the pedal bushing for wear and tear.

Yes

Replace pedal bush.

No

Step 4

Check whether the clutch master cylinder is seized or binding?

Yes

Replace the clutch master cylinder. Refer to

3.2.6.2

 

Clutch Master Cylinder Replacement

No

Step 5

Bleed  the  clutch  hydraulic  system.  Refer  to 

3.2.6.3

 

Hydraulic  Clutch  Bleeding

,  Does  clutch  fork  resume

normal actions?

Yes

System normal

No

Step 6

Check whether the clutch slave cylinder is seized or binding? (Under normal circumstances, cylinder should
be able to move freely.)

Transmission / Drive Axle

Clutch System

3-9

Yes

Replace the clutch slave cylinder. Refer to

3.2.6.7

 

Clutch Slave Cylinder Replacement

No

Step 7

Clutch master cylinder leaking internally?

Inspect for correct clutch pedal reserve.

(a)

Release the clutch pedal to the halfway position.

(b)

Apply the clutch pedal several times.

(c)

Inspect to ensure the clutch pedal reserve is correct.

Clutch pedal reserve?

Yes

Replace the clutch slave cylinder. Refer to

3.2.6.7

 

Clutch Slave Cylinder Replacement

No

Step 8

Remove the transmission assembly. Check whether the clutch driven plate is damaged? (Whether warp or
bend)

Yes

Replace the clutch driven plate. Refer to

3.2.6.5

 

Clutch Assembly Replacement

No

Step 9

Remove the transmission assembly. Check whether the clutch pressure plate is damaged? (Whether warp
or bend)

Yes

Replace the clutch pressure plate. Refer to

3.2.6.5

 

Clutch Assembly Replacement

No

Step 10

Remove the transmission assembly, check whether the clutch driven plate is biding on the transmission input
shaft axle?

Yes

Replace the clutch driven plate. Refer to

3.2.6.5

 

Clutch Assembly Replacement

No

Step 11

System normal.

3.2.5.3 Clutch Slipping

Fault Definition: When the first gear is selected and the clutch is fully engaged, the vehicle is difficult to start or can not
start.

Step 1

Check whether the clutch pedal height is correct, otherwise the clutch master cylinder can not be completely
reset. Measure the clutch pedal free travel. Refer to 

3.2.6.4

 

Clutch Pedal Free Travel Adjustment

.

3-10

Clutch System

Transmission / Drive Axle