Skoda Workshop Service and Repair Manuals

Fault finding power transmission - problems with the clutch and clutch control   Note t  Check hydraulic clutch control Octavia II → Chapter. t  Check hydraulic clutch control Superb II → 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 description	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 or slave cylinder leaking.	–  Replace defective component, vent air from the line system; top up with brake fluid.
	t  Release bearing is tilted on the guide bushing, seizured.	–  Replace guide bushing and release bearing.
	t  Membrane spring of the pressure plate broken.	–  Replace pressure plate.

Fault	Fault description	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  Release bearing is tilted on the guide bushing, seizured.	–  Replace defective components.
	t  Pressure plate with wrong spring identification.	–  Assign pressure plate via the → Electronic catalogue of original parts.
	t  Mechanical fault of the pressure plate/clutch disc.	–  Replace defective components.
	t  Clutch disc on the serration sluggish/jams.	–  Check serration of the hub for damage (burrs), if necessary replace clutch disc. –  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.

Fault	Fault description	Measure
Noises when operating the clutch.	t  Release bearing defective, guide of clutch release bearing not in order, contact surface drained off.	–  Always replace noisy release bearing. –  Replace guide bushings if damaged.
	t  The contact surface of the pressure plate is defective (the tips of the membrane spring are bent, broken). Release bearing is off-center.	–  Replace pressure plate. –  Check release bearing, guide bushing, replace if necessary. –  Check position of release lever. –  Check dowel sleeves.
	t  Centre displacement of engine/gearbox.	–  Check dowel sleeves.
	t  Clutch disc installed the wrong way up.	–  Correct installation.
	t  Wrong clutch disc installed.	–  Assign clutch disc via the → Electronic catalogue of original parts.

Fault	Fault description	Measure
Rattling, scratching occurs when the forward or reverse gear is engaged, gearschift jams, is sluggish, shifting is not possible, clutch without operation.	t  Air in the system, clutch does not separate fully.	–  Bleed system; check system, top up with brake fluid.
	t  Master/slave cylinder, line is leaking.	–  Replace defective component, top up with brake fluid, bleed system.
	t  The travel of the clutch pedal is not sufficent (carpet, foot mat under the foot controls), clutch is not fully depressed.	–  Inform customer.
	t  Pressure plate uneven due to incorrect installation, clutch disc warped due to improper handling.	–  Inspect parts, if necessary replace, observe position of the centering pins. –  If scratching still occurs, check the serration of the clutch disc on the drive shaft for ease of movement, if necessary repair the gearbox.
	t  Tips of membrane spring broken or bent (assembly fault, release bearing moves off-center).	–  Replace pressure plate. –  Check release bearing, guide bushing, replace if necessary. –  Check dowel sleeves.
	t  Clutch disc too thick.	–  Assign clutch disc via the → Electronic catalogue of original parts.
	t  Lining glued to the flywheel (long immobilization time, high humidity).	–  Slightly rub down friction surfaces of the clutch linings or replace completely the severely corroded parts.
	t  Clutch disc on the serration sluggish/jams. Corroded hub, damaged during assembly. Hub profile knocked out on one side.	–  Check serration of the hub for damage, if necessary replace clutch disc. –  Remove corrosion and traces of grease from hub and shaft. Grease shaft with grease for plug serration of clutch disc -G 000 100 -. –  Move clutch disc back and forth, remove excess grease. –  Check position of dowel sleeves on knocked out hub profile. –  Check release bearing, guide bushing and pressure plate, replace if necessary.
	t  Lifting of pressure plate too low (wrong pressure plate installed).	–  Assign pressure plate via the → Electronic catalogue of original parts.
	t  Displacement of engine/gearbox too large (dowel sleeves missing), support panel of clutch plate bent through this.	–  Insert dowel sleeves before gearbox has been fitted. –  Check clutch disc and pressure plate for damage, if necessary replace.
	t  Linings spalled off because of too high revs (shift back during too high speed). t  When starting, linings are spalled off through slipping for too long a time.	–  Replace clutch disc. Inform customer.

Fault	Fault description	Measure
Load change jolts when throttle is depressed and sudden reduction of the engine speed.	t  Assembly bearing is too soft.	–  Inform customer. Assign hanger via the → Electronic catalogue of original parts.
	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 description	Measure
Clutch slips through, no or bad predrive.	t  Wrong clutch disc, wrong pressure plate installed.	–  Assign the clutch disc and pressure plate via the → Electronic catalogue of original parts.
	t  Clutch disc worn out, burnt, pressure plate overheated, grooves, pressure plate deformed through incorrect assembly, compressive force 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 seals of engine or 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 radial shaft seal, remove excess grease from the drive shaft.
	t  Clutch disc installed the wrong way up.	–  Correct installation, check clutch disc, replace if necessary.
	t  Flywheel depth too large or excess removal at the base of the thrust surface.	–  Assign the sealing flange via the → electronic catalogue of original parts. –  Inspect clutch disc, pressure plate, replace if necessary.
	t  Slave cylinder leaking.	–  Replace slave cylinder.

Fault	Fault description	Measure
Clutch grabbing, unit shaking.	t  Air in the system.	–  Bleed system, check brake fluid level, check system for tightness. –  Replace defective part.
	t  Engine does not run clean.	–  Check engine setting, correct.
	t  Driving error, starting speed is too low.	–  Inform customer.
	t  Wrong clutch disc installed.	–  Assign clutch disc via the → Electronic catalogue of original parts.
	t  Assembly bearing too soft, knocked out.	–  Assign the assembly bracket via the → Electronic catalogue of original parts.
	t  Clutch lining, contact surface of pressure plate and flywheel oily (oil leakage from the clutch housing).	–  Check radial shaft seal of the drive shaft for clutch or check crankshaft, if necessary replace. –  Replace clutch disc, clean pressure plate and flywheel.
	t  Release bearing on the guide bushing is tilted, seizured (presses on one side onto the membrane springs of the pressure plate).	–  Replace release bearing and guide bushing. –  Check control elements and bearing for control elements.
	t  The contact surface of the pressure plate lifts off only unilaterally due to the tilted release bearing. t  Housing of the pressure plate warped when installed. Contact surface of the pressure plate lifts off only unilaterally.	–  Check the contact surface of the clutch lining at the flywheel, check pressure plate and membrane spring, replace pressure plate if necessary. –  Replace release bearing and guide bushing.
	t  Drive schaft too heavily greased (traces of grease on the clutch disc, pressure plate and flywheel).	–  Remove grease from pressure plate and flywheel, replace if damaged (traces of wear, traces of overheating, grooves). –  Remove traces of grease from hub and shaft, grease shaft with grease for plug serration of clutch disc -G 000 100-. –  Move clutch disc back and forth, remove excess grease.

Fault	Fault description	Measure
Acoustic knock »Klack« when coupling.	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 description	Measure
Noises in idle.	t  Torsional damper spring broken.	–  Replace clutch disc.
	t  Clutch disc without predamper installed (idle rattling).	–  Assign clutch disc via the → Electronic catalogue of original parts.
	t  Pressure plate warped, broken, imbalance.	–  Replace pressure plate.
	t  Irregular engine running.	–  Check engine setting, correct if necessary.
	t  Displacement of engine/gearbox too large (dowel sleeves missing).	–  Insert dowel sleeves before gearbox has been fitted.
	t  Spacer plate rubs on the flywheel.	–  Insert spacer plate on sealing flange and push onto the dowel sleeves.