DAF 95XF. Manual — part 446
3
DIAGNOSIS
Gearbox, mechanical
5-2
FAULT: GEAR LEVER STUCK IN GATE 3/4
Possible cause
Remedy
Oil leak in gate safety piston
Replace the O-ring
FAULT: SINGLE H BECOMES DOUBLE H
Possible cause
Remedy
Locking plate in control cover incorrectly fitted
Check composition of control cover
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3
Clutch
DIAGNOSIS
6-1
6. CLUTCH
6.1 FAULT-FINDING TABLE
FAULT: CLUTCH PEDAL FAILS TO RETURN
Possible cause
Remedy
Broken pedal return spring
Replace spring
Worn clutch pedal bearing
Check bearing and replace, if necessary
Dirt in hydraulic system
Clean system and fill with fresh fluid
Incorrect fluid in hydraulic system
Replace by fluid with correct specification
Air in hydraulic system
Bleed the system
FAULT: CLUTCH PEDAL STICKS WHEN DEPRESSED
Possible cause
Remedy
Leak in hydraulic system
Check system
Air in hydraulic system
Bleed hydraulic system
Declutching bearing incorrectly fitted
Fit declutching bearing correctly
Fork hinge points or fork itself pressed in
Check hinge points and fork, replace if
necessary
Defective clutch servo
Repair and/or replace clutch servo
Sliding bush pressed in or broken
Check, replace sliding bush
FAULT: PEDAL FORCE TOO HIGH
Possible cause
Remedy
No or insufficient pressure in circuit 4 of the
brake system
Check circuit 4 of the brake system
Air pipe kinked
Check pipe and replace, if necessary
Hydraulic line kinked
Check line and replace, if necessary
Worn clutch pedal bearing
Check bearing and replace, if necessary
Defective clutch servo and/or master cylinder
Repair or replace clutch servo and/or master
cylinder
Note: Clean system and fill with fresh fluid in
case of a swollen sealing
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3
DIAGNOSIS
Clutch
6-2
FAULT: RESIDUAL PRESSURE IN CLUTCH SYSTEM
Possible cause
Remedy
Vent opening in reservoir cap blocked
Check reservoir cap vent opening
Balance hole in master cylinder blocked by
swollen sealing or insufficient free travel of push
rod
Check free travel of push rod or repair or
replace master cylinder
Note: Clean system and fill with fresh fluid in
case of a swollen sealing
FAULT: FLUID LEAKAGE VIA VENT OPENING
Possible cause
Remedy
Leakage via piston sealing in clutch servo
Repair or replace clutch servo
Note: Finding a drop of oil at the ventilation
opening is normal and is no reason to replace or
repair the clutch servo
FAULT: CLUTCH PLATE SLIPS
Possible cause
Remedy
Worn lining
Replace lining
Oil on lining
Replace lining and check engine and gearbox
sealing rings
Dirt on clutch plate and flywheel
Clean plate and surrounding area
Burnt clutch plate
Check entire clutch and replace, if necessary
Clamping force of clutch release assembly too
low or absent
Check clutch release assembly and replace, if
necessary
Clutch release assembly is not released
Check clutch release assembly
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3
Clutch
DIAGNOSIS
6-3
FAULT: CLUTCH RELEASE ASSEMBLY FAILS TO RELEASE
Possible cause
Remedy
Fluid level in hydraulic system too low
Top up fluid
Incorrect pedal setting
Check setting and correct, if necessary
Air in hydraulic system
Bleed hydraulic system
Leak in hydraulic system
Check hydraulic system
Fingers of clutch release assembly broken
Replace clutch release assembly
Wrong clutch release assembly has been fitted
Fit correct clutch release assembly
Clutch fork is broken
Replace fork
Clutch release assembly severely contaminated
Clean entire clutch assembly
Defective clutch servo
Check clutch servo and replace, if necessary
Thrust bearing incorrectly fitted
Fit thrust bearing correctly
Clutch housing disconnected from gearbox
Tighten the clutch housing bolts to the correct
torque
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