Skoda Workshop Service and Repair Manuals

Fault finding power transmission - problems with the clutch and clutch control   Note Check hydraulic clutch control → Chapter. Before each clutch repair, examine and reconstruct the complaint of the customer. In each individual case, it must be determined if indeed there are problems with the clutch or the incorrect setting of the gearshift is cause for complaint.

Fault	Fault type	Measure
Clutch pedal does not return to initial position.	t  Air in line system.	–  Vent air from the line system; top up with brake fluid.
	t  Line system, master cylinder or slave cylinder leaking.	–  Replace defective component, vent air from the line system; top up with brake fluid.
	t  Membrane spring of the pressure plate broken.	–  Replace pressure plate.

Fault	Fault type	Measure
Actuating force on the clutch pedal too high.	t  Over-centre helper spring defective.	–  Replace over-centre helper spring.
	t  Clutch release force increased due to wear of clutch linings.	–  Inform customer (higher release force with increased wear). –  Replace clutch disc, when the distance base/rivet is below 0.1 mm.
	t  Pressure plate with wrong spring identification.	–  Assign pressure plate according to → Electronic Catalogue of Original Parts.
	t  Mechanical fault at the pressure plate or the clutch disc.	–  Replace defective parts.
	t  Clutch disc on the serration sluggish/jams.	–  Check serration of the hub for damage (burrs). Replace the clutch disc if necessary. –  Clean the hub and the drive shaft serration from corrosion and residues of lubricant and grease with grease for plug serration of clutch disc -G 000 100 -. Move clutch disc back and forth, remove excess grease.
	t  Clutch push rod and release plate (pressure plate) sluggish.	–  Lightly grease contact points with grease for plug serration of clutch disc -G 000 100-. –  Lightly grease clutch push rod.

Fault	Fault type	Measure
Clutch control noises.	t  Release bearing defective.	–  Replace release bearing.
	t  Centre displacement of engine/gearbox.	–  Check dowel sleeves.
	t  Clutch disk incorrectly mounted.	–  Correct the fitting.
	t  Wrong clutch disc installed.	–  Use the → Electronic Catalogue of Original Parts for the assignment of the clutch disc.

Fault	Fault type	Measure
Scratch noises when the forward or reverse gear is engaged, gearschift jams, hooks, is sluggish, shifting not possible, clutch without operation.	t  Air in the system, clutch does not separate fully.	–  Check and bleed system, top up with brake fluid.
	t  Master cylinder or slave cylinder is leaking, line is leaking.	–  Replace defective component, top up with brake fluid, vent air from the system.
	t  The travel of the clutch pedal is not sufficent (carpet, foot mat under the pedal), pedal is not fully depressed.	–  Inform customer.
	t  Pressure plate uneven due to incorrect installation, clutch disc warped due to improper handling.	–  Check components, if necessary replace, make sure the centering pins are correctly fitted. –  If afterwards scratching still occurs, check the serration of the clutch disc on the drive shaft for ease of movement, if necessary carry out gearbox repair.
	t  Clutch disc too thick.	–  Use the → Electronic Catalogue of Original Parts for the assignment of the clutch disc.
	t  Lining glued to the flywheel (long immobilization time, high humidity).	–  Slightly rub down the friction surfaces of the clutch lining, if necessary when corrosion occurs in a larger area, replace the component completely.
	t  Clutch disc on the serration sluggish/jams. Corroded hub, damaged during assembly. Hub profile knocked out on one side.	–  Check the hub for damage, if necessary replace the clutch disc. –  Remove corrosion from the hub and the shaft as well as residues of lubricant. Lightly grease shaft with grease for plug serration of clutch disc -G 000 100 -. –  Move clutch disc back and forth, remove excess grease. –  Check the position of the dowel sleeves when the hub profile is knocked out.
	t  The stroke of the pressure plate is too low (wrong pressure plate installed).	–  Use the → Electronic Catalogue of Original Parts for the assignment of the pressure plate.
	t  Displacement of engine/gearbox too large (dowel sleeves missing), support panel of clutch plate bent through this.	–  Before installing the gearbox, insert the dowel sleeves. –  Check clutch disc and pressure plate for damage, if necessary replace.
	t  The lining is spalled off because of too high revs (shift back into lower gears during high speeds). t  When starting, linings are spalled off through slipping for too long a time.	–  Replace clutch disc. Inform customer.
	t  Clutch push rod too short due to wear.	–  Replace clutch push rod. Check release bearing, replace if necessary. –  Lightly grease contact points of clutch push rod to release bearing with grease for plug serration of clutch disc -G 000 100 -.

Fault	Fault type	Measure
Load alteration shocks when pushing the accelerator pedal down sharply and when the engine speed drops suddenly.	t  Assembly bracket is too soft.	–  Inform customer. Use the → Electronic Catalogue of Original Parts for the assignment of the hanger.
	t  Irregular engine running.	–  Check engine setting, correct.
	t  Clutch disc with predamper is built in against gear rattling.	–  Inform customer.
	t  Centre displacement of engine/gearbox.	–  Test dowel sleeves, replace if necessary.

Fault	Fault type	Measure
Clutch slips, no or poor acceleration	t  Wrong clutch disc fitted, wrong pressure plate installed.	–  Use the → Electronic Catalogue of Original Parts for the assignment of the clutch disc and the pressure plate.
	t  Clutch disc worn out, burnt, pressure plate overheated, scoring, pressure plate warped through incorrect assembly, contact pressure of the pressure plate too low, driving error, natural wear.	–  Replace clutch disc. –  Replace pressure plate. –  Inform customer.
	t  Clutch disc, pressure plate, flywheel - oily. Shaft seal of the engine or the gearbox defective. Grease on the contact surface through excess greasing of the hub.	–  Replace clutch disc. –  Clean contact surfaces of pressure plate and flywheel. –  Replace shaft seal, remove excess grease from the drive shaft.
	t  Clutch disk incorrectly mounted.	–  Correct the fitting, check clutch disc, replace if necessary.
	t  Gasket ring for push rod in the drive shaft leaks. Bearing bushing for push rod in the drive shaft knocked out.	–  Replace gasket ring, clutch disc. –  Check bearing bushing for clutch push rod, replace if necessary. –  Clean pressure plate, flywheel.

Fault	Fault type	Measure
Clutch grabbing, unit shaking	t  Air in the system.	–  Bleed system, check brake fluid level, check system for leaks. –  Replace defective part.
	t  Engine does not run clean.	–  Check engine setting, correct.
	t  Driving error, speed too low when starting.	–  Inform customer.
	t  Wrong clutch disc installed.	–  Use the → Electronic Catalogue of Original Parts for the assignment of the clutch disc.
	t  Assembly bracket too soft, knocked out.	–  Use the → Electronic Catalogue of Original Parts for the assignment of the assembly bracket.
	t  Clutch lining oily, contact surface of pressure plate and flywheel oily (oil leakage from the clutch housing).	–  Check shaft seal of the drive shaft for clutch or check crankshaft, if necessary replace. –  Replace clutch disc, clean pressure plate and flywheel.
	t  Drive schaft too heavily greased (traces of grease on the clutch disc, pressure plate and flywheel).	–  Clean pressure plate and flywheel free of grease, replace in the event of damage (traces of wear, overheating, grooves). –  Remove traces of grease from hub and shaft, grease shaft lightly with grease for plug serration of clutch disc -G 000 100-. –  Move clutch disc back and forth, remove excess grease.

Fault	Fault type	Measure
Acoustic load alteration shock “clicking” when coupling (release clutch pedal).	t  Carrier earth/drive shaft is accelerated with sudden coupling. The drive shaft serration of the pinions in mesh knocks; for clutch discs with predamper the noise increases as the predamper reaches the stop.	–  Inform customer.

Fault	Fault type	Measure
Noises in idle.	t  Torsional damper spring broken.	–  Replace clutch disc.
	t  Clutch disc fitted without predamper (idle rattling).	–  Use the → Electronic Catalogue of Original Parts for the assignment of the clutch disc.
	t  Pressure plate warped, broken, imbalance.	–  Replace pressure plate.
	t  Irregular engine running.	–  Check engine setting, correct if necessary.
	t  The displacement of the engine to the gearbox is too large (dowel sleeves are missing).	–  Before installing the gearbox, insert the dowel sleeves.
	t  Intermediate plate rubs on the flywheel.	–  Insert intermediate plate on sealing flange and push onto the dowel sleeves.