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Tips for the proper handling of clutches.

Installing clutches

If you observe only a few decisive details during clutch replacement, you can mostly save a lot of time and high costs and avoid unhappy customers.

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Check clutch disks

Workshops may receive damaged new clutch disks due to a lack of care during transportation. Therefore, ZF Services recommends new parts are also tested for lateral runout.

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Greasing the hub spline of clutch disks

Only an optimally greased hub spline on the clutch disk ensures faultless functioning of the clutch in the long term.

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Clutch noise

Clutch noise such as whistling or clonking is not always an indication of a defective clutch. Whistling noises are generated by off-center contact with the clutch release bearing, a non-centered transmission input shaft, or a defective pilot bearing.

Rattling noises may be due to load alterations if clutch disks are furnished with preliminary dampers. These noises do not impair the function or service life of the clutch disk.

Additional possible causes include installation of the wrong parts, or installation of the clutch disk in the wrong position.

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Clutch grabs

If the clutch grabs, the problem may not necessarily lie with the clutch itself. Worn engine mounts or poor engine adjustment can also prevent smooth clutch engagement.

Installing the wrong clutch disk can also cause the clutch to grab.

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Clutch slips

Clutch slipping may have various causes. Besides the clutch pressure plate and the clutch disk, the problem is often found in the releasing system. Additional causes include an incorrectly remachined flywheel or installation of the wrong clutch.

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Clutch does not disengage

If the clutch does not disengage, the problem is not necessarily the clutch itself. Frequent causes include faults in the release system, a jammed pilot bearing, or non-compliance with important installation requirements.

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Checking DMF

If defects are suspected in the dual-mass flywheel (DMF), the cause study begins. If the fault diagnostics options are not sufficient for the installed DMF, the DMF can also be examined visually, mechanically, or on a test bench, although this latter possibility remains a task for the manufacturer. Any workshop can check a dismantled dual-mass flywheel with simple tools. It is important to know the right methods.

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Tips for the proper handling of suspensions.

Installing shocks and dampers free from distortion

Improper assembly or accidents can lead to distortion of shocks and dampers and later to serious component damage. ZF Services describes what to pay attention to during inspection and installation.

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Impact damage to shocks and dampers

Accidents or major installation errors can cause severe damage.


  • Carefully inspect damage to axles and shock absorber/damper attachments.
  • Measure axle alignment.
Shocks and dampers leak

Although a shock absorber or damper may appear to have a leak, this may not in fact be the case. A certain amount of "perspiration" is normal, and even necessary to lubricate the piston rod seal. Never diagnose shocks and dampers after the vehicle has been driven in the rain - they should be dry.

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