Test results

- Carry out a driving cycle simulating a hilly/urban route with frequent gear chages to heat up the clutch/engine assemblies.

Assess the problem in the following usage conditions:

- with the vehicle speed constant in 3rd or 4th gear and the engine speed about 4/5 of max torque, accelerate the engine rapidly with the accelerator pedal fully pressed.

- carry out departures from stationary on a flat surface, re-engaging the clutch and accelerating gradually from an initial engine speed of 1000-1500 rpm.

Move on to Step 1

Clutch pedal disconnected from transmission

 Op. 3330B26 CLUTCH PEDAL - R+R

check that the travel is free and there is no sticking or hardening

Move on to Step 2

Clutch pedal clearance or hardening

Replace the pedal

 Op. 3330B26 CLUTCH PEDAL - R+R

With the system disconnected, check that the travel is correct when the pedal is pressed and released.

Move on to Step 3

1. Hydraulic pump malfunction

2. Delivery hose to clutch control cylinder worn or distorted

1. Replace the pump

 Op. 1820B20 MASTER CYLINDER (PUMP) - R + R

2. Replace the hose

 Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R

The thrust bearing offset mark on the diaphragm spring may indicate that the centring is not correct.

Move on to Step 4

Thrust bearing not correctly centred.

Replace the thrust bearing.

Visually inspect the condition of the clutch assembly, making sure that there are no breaks and/or signs of overheating on the pressure plate, and no obvious deterioration of the driven disc or grease/oil on the friction surfaces.

Move on to Step 5

1. Obvious deterioration of the clutch plate and/or pressure plate broken.

2. Clutch plate with vitrified seal.

3. Oil or grease on the disc

4. Diaphragm spring broken.

1. Replace the assembly

 Op. 1810A20 CLUTCH - R + R

2. Replace the assembly

 Op. 1810A20 CLUTCH - R + R

3. Replace the assembly

 Op. 1810A20 CLUTCH - R + R

4. Replace the assembly

 Op. 1810A20 CLUTCH - R + R

Check the following, in order:

- for excess grease on the clutch plate hub bushes and the gearbox main shaft;

- the condition of the main shaft and hub.

Move on to Step 6

Main shaft damaged, hub worn, excess grease on the bushes.

Replace the assembly and/or main shaft

Check the condition of the flywheel.

In particular, check:

- the state of the surface;

- wear;- cuts;

- presence of grease/oil on the disc surfaces;

- signs of overheating.

End of diagnosis

1. Flywheel damaged.

2. Presence of dust in the flywheel friction ring.

1. Replace the flywheel

 Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX

2. Remove the dust from the flywheel friction seal.