Returns that will not be accepted

under Valeo Warranty

DAMAGE TO RETURN STRAPS
The function of the retaining straps (springs) is to hold the pressure plate to the cover
assembly and to lift the pressure plate when the diaphragm spring is depressed.
Symptoms:
Unable to select gear or ‘crunching’ when selecting gears.
Causes:
• Dropping the cover.
• Incorrect tightening sequence.
• Reverse engine torque.
Recommendations:
Visually check straps for damage. Valeo will not accept returns that have been fitted
with this fault.

WORN DIAPHRAGM FINGERS

The clutches in most modern vehicles are designed to run with the bearing in
constant contact with the diaphragm fingers (Preload).
Symptoms:
Noisy bearing, vibration on pedal, jerky pedal action.
Causes:
Both excessive and insufficient preload can be caused by:
• Worn or stiff release cable.
• Worn or seized pivot points (bushes).
• Wear to the pedal box.
• Incorrect setup of cable.
• Missing preload spring.
• Driver resting foot on pedal.
Recommendations:
Replace cables and bushes when changing the clutch. Check all parts of the
release mechanism including setting pedal height to manufacturers specification.

BURNT OR MISSING FRICTION MATERIAL

Friction material transfers power through the clutch assembly and absorbs thermal energy generated by differences in engine and
gearbox speed during normal road use.
Symptoms:
Clutch slip, burning smells
Causes:
• Vehicle or Driver Induced Slip
• Dropping downin the
Pulling away wrong gear
• Holding vehicle on incline
gears too quickly
• Over revving to free stuck with the clutch
• Defects on release mechanismvehicle
•
Recommendations:
Check release mechanism for defects replace recommended parts. Advise Driver of reasons behind failure
 BROKEN DRIVE PLATE
Sprung segment plates transfer torque between the friction material and the damper
springs.
Symptoms:
Total loss of drive, possibly with grinding noise from bellhousing.
Causes:
• Misalignment of input shaft during installation.
• Missing or wornof gearbox
Misalignment engine to gearbox.
• Flexing of input shaft duedowels.
• to worn spigot or primary shaft bearing.
Recommendations:
Check all dowels are in good condition and in place and gearbox is fully mated to the Damaged dowel
engine. Check for excess movement on input shaft. Always use a transmission jack
during gearbox installation.

CONTAMINATION OF FRICTION MATERIAL

The friction material transmits torque best when it is clean and dry.
Symptoms:
Juddering or slipping clutch. On inspection the plate will be darkened and may smell of oil.
Fig.1. You may see grease radiating out from the centre hub Fig.2.
Causes:
Fig.1 • Leaking from main oil seal.
• Hydraulicfrom
Leaking gearbox oil seal.
• Over greasing
leaks on concentric slave cylinders.
• of input shaft or bearing.
Recommendations:
Always check for leaks or contamination in the bellhousing. Rectify before installing
replacement clutch. Keep lubrication of input shaft splines to a minimum wipe away excess.
Valeo does not recommend the use of copper based grease for clutch
Fig.2 applications as the melting point is too low.

BROKEN SPLINED HUB

The splined hub transmits torque from the damper springs to the gearbox input shaft.
Symptoms:
Unable to select gears. Engine locked up in extreme cases.
Causes:
• Splines on input shaft have not cleanly entered splined hub on drive plate.
• Splines have not mated at all, but gearbox has been ‘pulled up’ to engine.
Recommendations:
Always use a transmission jack during gearbox installation. Rotate drive shaft
flange not the box to align splines. Ensure gearbox is fully mated to engine before
beginning tightening sequence. Never use impact tools to overcome resistance.

For more information see explanatory video clips on www.valeoservice.co.uk

www.smileyouaredriving.com www.valeoservice.co.uk

Valeo Service (UK) Ltd,

Heming Road, Washford, Redditch,
Worcestershire, B98 0DZ
Tel : 01527 838300
Fax : 01527 523732