About Us -- AltoUSA.com

Return Home

One Alto Way
Atmore, AL 36504

EMAIL:
sales@altousa.com

PHONE:
251.368.7777

FAX:
251.368.7774

Tools Required

The replacement of the clutch system requires basic hand tools for most of the operation. There are, however, a few specialty tools that simplify the removal and installation of certain components of the clutch system. Alignment tools work very well in aligning the clutch disc and pilot bearing. This provides for the easy installation of the transmission. AltoStandard Clutch Kits include a plastic alignment tool for your convenience.

A pilot bearing puller makes the removal of the pilot bearing/bushing very easy. If you do not have one of these, they can be rented at several equipment rental centers. For your own safety, if you do not have access to a vehicle hydraulic lift we strongly recommend you support the vehicle with jack stands. Never work under any vehicle supported by only a jack.

Pre-inspection

Before beginning the clutch system replacement, there are a series of inspections you should perform prior to the clutch removal. Most clutch failures occur on a vehicle after 60,000 miles. The need for a clutch replacement prior to that is unusual and should be investigated.

If the clutch system is slipping, a simple adjustment could correct the problem. As the friction material wears, the fingers (diaphragm) of the cover assembly move closer to the bearing. To maintain the correct bearing lash, the bearing needs to be adjusted backwards away from the cover assembly. If the release system is hydraulic, it is possible that the clutch master cylinder needs to be replaced. Master cylinders have a valve that allows the return of fluid back into the reservoir to allow the bearing to move back away from the cover assembly. You can check this if the system has an external slave cylinder. Detach the slave cylinder from the bellhousing. Remove the top of the master cylinder. Have someone look at the reservoir as you push the piston of the slave cylinder back into the slave cylinder. If the fluid does not return back into the reservoir, the master cylinder needs to be replaced.

If the clutch system is not releasing, the following inspections should be made. If the release system is hydraulic, inspect the master cylinder reservoir fluid level. If it is dry, inspect the master cylinder and the slave cylinder for fluid leaks. If no leaks are found then refill reservoir and examine again after driving the vehicle a short distance. You should also inspect the transmission mounts and motor mounts to be sure they have not broken. Broken mounts can misalign the engine and transmission and prevent the release of the clutch disc. Replace these if necessary. Also, if the vehicle has recently been involved in a collision and clutch release problems occurred after that event, it is possible that the frame is damaged and is causing a misalignment of the engine and transmission. If a clutch release cable operates the system, attempt to adjust the cable so that the bearing is moved closer to the cover assembly. If there is no additional adjustment on the cable, it is possible that the cable has stretched. Replace the cable and test before removing the clutch. It is recommended to replace the cable with every clutch system replacement.

If the clutch system has a bearing noise, a simple test can identify which bearing is creating the problem. Sit in the vehicle and start the engine. With the engine running and the transmission in neutral and both feet on the floorboard, listen for the bearing noise. If the noise is heard at this point, the bearing creating the noise is in the transmission because the clutch release bearing and pilot bearing are not moving at this time. Next place your foot on the clutch pedal and begin to depress the pedal half way down. If the bearing noise is heard at this point, the bearing making the noise is the clutch release bearing. The pilot bearing is not moving at this point. If after depressing the clutch pedal all the way to the floorboard the bearing noise is heard, the bearing creating the problem is the pilot bearing or bushing. By doing this simple test you can identify the problem before removing the clutch system.