Checking & adjusting a clutch

Part 1. Preparation and safety

Objective

• Check and adjust a clutch to make sure it complies with the manufacturer's specification.

Personal safety

Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:

• Work clothing - such as coveralls and steel-capped footwear
• Eye protection - such as safety glasses and face masks
• Ear protection - such as earmuffs and earplugs
• Hand protection - such as rubber gloves and barrier cream
• Respiratory equipment - such as face masks and valved respirators

If you are not certain what is appropriate or required, ask your supervisor.

Safety check

• Make sure the vehicle's emergency brake is applied.
• Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.

Points to note

• As the clutch plate wears, it becomes thinner. This results in the release lever moving closer to the release bearing and the clutch cable loses its operational clearance.
• Some clutches are self-compensating for wear, while others require checking and adjusting.

• You must refer to the manufacturer's shop manual to find out exactly where any adjustment should be made.

Part 2: Step-by-step instruction

1. Check clutch free play.
   Lightly push down on the clutch pedal, approximately 1”, or 2.5cm, until it meets resistance. Refer to the manufacturer’s specification for your make and model to discover the location point for any adjustment.
2. Adjust the free play.
   Cable or mechanical systems may require an adjustment to the length of the cable housing. Most hydraulic systems are self-adjusting, but those that are not may require an adjustment to be made at the slave cylinder push rod. Make the relevant adjustment, which is normally done by loosening a jam nut and then moving an adjusting nut on a rod that locates on the clutch pivot arm or by loosening a jam nut on the outer clutch cable and adjusting the cable in relation to its fixture bracket to the manufacturer’s specification, and recheck the pedal travel. When adjusted correctly, retighten the jam nut. Hydraulic systems should also be checked for fluid leaks.
3. Check the adjustment
   Start the vehicle and depress the clutch. Make a gear selection to ensure the gears do not grate going into mesh. While in gear, slowly release the clutch and see how far the pedal must travel before the clutch starts to take up. If it is not within the manufacturer’s specification discuss it with your supervisor.