RETURNS THAT WILL NOT BE ACCEPTED UNDER VALEO ...

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
Pulling away in the wrong gear
Dropping down gears too quickly
Holding vehicle on incline with the clutch
Over revving to free stuck vehicle
• Defects on release mechanism
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.
Misalignment of engine to gearbox.
Missing or worn gearbox dowels.
• Flexing of input shaft due 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
engine. Check for excess movement on input shaft. Always use a transmission jack
during gearbox installation.
Damaged dowel
CONTAMINATION OF FRICTION MATERIAL
Fig.1
Fig.2
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:
Leaking from main oil seal.
Leaking from gearbox oil seal.
Hydraulic leaks on concentric slave cylinders.
• Over greasing 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
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