The Clutch Disengages Incompletely

Handling
Fault description Fault cause
measure

1. The free stroke 1. Adjust the

of the clutch pedal stroke of clutch
is too big. pedal.
2. Clutch hydraulic 2. Adjust or repair
control related systems.
mechanism has oil 3. Adjust and
leakage, oil replace relevant
shortage or air in parts.
the system. 4. Repair or
3. Release shifting replace damaged
1. When the
fork is deformed, originals.
engine is idling, it
making it difficult 5. Lubricate,
is difficult to
to adjust the adjust and replace
depress the clutch
height of the inner relevant parts.
pedal and engage
end of the release 6. Correct or
gears,
shifting fork. replace relevant
accompanied by
4. There are parts.
gear impact
phenomena such
sound. The vehicle
as warping of the
starts or the
steel plate of the
engine shuts down
follower disk,
before the clutch
rupture of the
is lifted when the
friction plate or
gearshift lever is
loosening of the
barely engaged.
rivets.
2. When the
5. There is
vehicle is running,
stagnation during
it is difficult to
the movement of
shift gears and still
the spline hole of
accompanied by
the driven plate
gear impact
and the spline
sound.
shaft of the first
axis of the
transmission.
6. Whether the
pressure plate
spring has uneven
elasticity or
whether some
springs are
broken.

1. Check the stroke of clutch pedal.

The free stroke of clutch pedal is too big, which can result in incomplete clutch
disengagement.
Measure the stroke of clutch pedal to see if it is within the standard value range.
Measurement of the free stroke of clutch pedal, 离合器踏板的自由行程调整 For detailed
：
information,See Page "". Free Stroke Adjustment of Clutch Pedal .
A. Yes, proceed to the next step.
B. No, adjust the stroke of clutch pedal.

2. Check the clutch hydraulic control mechanism.

1) Is there any oil leakage from the clutch control mechanism?

A. Yes, replace or repair leaking

hydraulic elements.

B. No, perform the next step.

1. Clutch master pump oiler

图1
2) Check brake fluid in clutch master pump oiler (1).

The clutch master pump oiler (1) is

located at the bottom of the brake clutch
pedal. Open the cab and the front face
shield can be found.

Is the fluid in the clutch master pump

oiler (1) too low?

A. Yes, add brake fluid to between the

min and max lines.

The brake fluid model is: DOT3 or

DOT4.

CAUTION

• Use the specified brand of brake

fluid to prevent damage to
hydraulic elements.
 • Brake fluid is corrosive. If it is
accidentally spilled, wipe it off
immediately, otherwise it might
cause damage to other parts.

B. No, perform the next step.

2. Clutch booster

3. Exhaust valve
图2
3) Check whether the hydraulic system is mixed with air.

A. Yes, air is removed from the system

through the exhaust valve (3) on top of
the clutch booster.

B. No, perform the next step.

图3
3. Remove the transmission housing, inspect release shifting fork.
1)Is release shifting fork deformed, making it difficult to adjust the height of the inner ends
of release shifting fork?
A. Yes, adjust and replace relevant parts.
B. No, perform the next step.
2)Is release shifting fork improperly adjusted so that the inner ends are not in the same
plane or the height of the inner ends is too low?
A. Yes, adjust release shifting fork.
B. No, perform the next step.
4. Check the driven plate.
1)Does the driven plate steel have warped plates, cracked friction plates, or loose rivets?
A. Yes, repair or replace damaged components.
B. No, perform the next step.
2)Are the new friction plates on the driven plates too thick?
A. Yes, adjust the distance between flywheel and pressure plate by adjusting shim.
B. No, perform the next step.
3)Is there stagnation during the movement of the spline hole of the driven plate and the
spline shaft of the first axis of the transmission.
A. Yes, lubricate, adjust, and replace relevant parts.
B. No, perform the next step.

5. Inspection pressure plate.

Is there uneven elasticity, weakened spring force, or individual spring breakage in pressure
plate spring?
A. Yes, correct or replace relevant parts.