The customer complaint is that the clutch slips or that he or she is unable to select gears.
- Possible reasons for clutch failure:
- Worn clutch
- Incorrect procedure for clutch replacement
- Incorrect clutch fitted
- Incorrect adjustment of clutch actuator
- Damaged or seized clutch actuator
- Poor voltage supply to transmission control module (TCM)
- Poor ground to TCM
- Battery support / charger voltage set too high or too low
- Water damage to TCM
- Damaged or seized gear selection actuator
- Incorrect removal procedure carried out
- Internal transmission failure – gears or synchros worn
Warning: Do not place hands near any transmission actuators while battery is connected as these may move suddenly or randomly.
Caution: Follow the procedure below when removing the clutch actuator for any transmission or clutch repair. Failure to do so could cause permanent damage to clutch actuator.
- In the engine bay, check the clutch actuator on the front of the transmission.
- Check that the actuator pin is in contact with the clutch fork.
- If the fork is loose the clutch bearing may have been destroyed. In this case, the clutch actuator may not activate and set itself to removal position. If this is the case, replace the complete clutch and clutch actuator.
- Select your vehicle model in AssistPlus:
- Select DRIVETRAIN + ALTERNATOR >> GEARBOX
- The correct selection of gearbox should read BVMP MA or BVMP. If this is not the case, press cancel and manually select this option.
- When CONTINUE is selected, note the warning message and press OK. If the battery is low, attach a battery charger set to no more than 12.5V, or use jumper leads from another vehicle with the engine running.
- On the transmission menu, select SPECIFIC COMMANDS >> ACTUATOR REMOVAL POSITION.
- Read the onscreen instructions and press NEXT.
- Read the instructions and press FINISH.
- Allow the activation to complete. Once done, press OK to exit.
- In the engine bay, check the clutch actuator position. This should be as shown below:
- Once the clutch actuator pin is in the correct position, wait 3 minutes. You can then safely disconnect the vehicle battery, detach the transmission actuators and remove the transmission to inspect the clutch.
- If the clutch has just been replaced, follow the refitting procedure below.
Refit the clutch, gear selection actuator, clutch actuator and battery. At this stage, do not fully tighten the clutch actuator securing bolts.Manually adjust the clutch actuator:• Slacken the securing / adjustment bolts to allow the clutch actuator to move freely on its mounting bracket.• Push the clutch actuator forward towards the transmission clutch fork.• Remove all slack from clutch actuator pin and clutch fork.• Slightly tighten the securing/adjustment bolts.• The clutch bearing should now be in contact with the clutch pressure plate.
Electronic adjustment of clutch actuator (step 1):
• Using the AssistPlus, select your vehicle model.
• From the model selections screen, choose DRIVETRAIN + ALTERNATOR.
• Select GEARBOX.
Note: The correct selection of gearbox should read ‘BVMP MA or BVMP.’ If this is not the case, press cancel and manually select this option.