2398749 - E01 CLUTCH NOT RELEASING CORRECTLY

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Results of the tests
0PRELIMINARY CHECKSAll OKProblems metOperation
With the engine idling, check whether the fault is present when all gears are engaged.Eliminate any obstacles preventing the correct travel of the clutch pedal (position of mats, cable interference, etc.).Continue to Step 1The fault occurs only when some gears are engaged.Continue according to the instructions for the See table   C02  GEAR ENGAGEMENT OR RELEASE DIFFICULT
1CHECK ON CLUTCH LEVER TRAVELAll OKProblems metOperation
Check, inside the engine compartment, that when the clutch pedal is pressed, the clutch control lever on the gearbox performs the correct travelContinue to Step 8Incomplete travel of clutch lever on gearboxContinue to Step 2
2VISUAL CHECK FOR LEAKSAll OKProblems metOperation
Carry out a visual inspection of the operating cylinder and pipesCheck that there are no leaks or damageContinue to Step 3Leaks or damage on pipes and/or hydraulic connectionsRenew damaged or faulty components.
3CHECK FOR PRESENCE OF AIR IN CLUTCH HYDRAULIC SYSTEMAll OKProblems metOperation
Adjust the bleed screw on the operating cylinder to check that the system is free of airContinue to Step 4Presence of air in the hydraulic systemBleed the air Continue to Step 4
4CHECK ON CLUTCH CONTROL SYSTEM (ON CAR)All OKProblems metOperation
Release the cylinder from the clutch control lever, keeping it connected to the hydraulic system. Press the pedal to induce the thrust pressure and check the pushrod travel Push the pushrod back in using a punch, checking that it travels freelyContinue to Step 5Malfunction of clutch control cylinderRemove the clutch operating cylinder Op.   1820B30  Continue to Step 5
5CHECK ON CLUTCH CONTROL CYLINDER (WITH GEARBOX REMOVED)All OKProblems metOperation
With the part at the bench, apply pressure (with compressed air) and check the pushrod travel (The test mirrors what was done on the car)
The purpose of this test is to make sure that the fault is in the cylinder and not the pipes or pump
Continue to Step 6Malfunction of clutch control cylinderReplace the clutch operating cylinder Op.   1820B30 
6CHECK ON CLUTCH PEDAL TRAVELAll OKProblems metOperation
With the system disconnected, check that the travel is correct when the pedal is pressed and releasedContinue to Step 7Malfunction of hydraulic pumpReplace the pump Op.   1820B20 
Hose from clutch reservoir to pump worn or deformedReplace the pipe Op.   1820B40 
Supply hose to clutch operating cylinder worn or deformedReplace the pipe Op. 1820B48
7CHECK ON CLUTCH PEDALAll OKProblems metOperation
After disconnecting the clutch pedal from the transmission check that it travels freely with no stiffness or tight spotsContinue to Step 8Play or stiffness on clutch pedalReplace the pedal Op.   3330B26 
8CHECK ON CLUTCH RELEASE LEVER AND BEARING (WITH GEARBOX REMOVED)All OKProblems metOperation
After removing the gearbox, check that the lever is not stiff (because of dirty or insufficient lubrication) and that the clutch release bearing runs freely in its seating and shows no signs of damageContinue to Step 9The presence of dirt or wear caused by insufficient lubrication does not allow the clutch release bearing to slide correctlyReplace the faulty or damaged parts
9CHECK ON CLUTCH ASSEMBLYAll OKProblems metOperation
Visual check on the condition of the clutch assembly, on which there should be no breaks (pressure plate) and/or obvious damage (driven plate) Measurements with gauge as per manualContinue to Step 10Obvious damage of clutch disc and/or breakage of pressure plateReplace the assembly Op.   1810A24 
10CHECK ON SPLINED CLUTCH HUBAll OKProblems metOperation

Check, in order:

  • that there is no excess grease on the clutch plate hub bushes and the gearbox main shaft;
  • condition of hub and main shaft
Continue to Step 11Main shaft damaged, hub worn, excessive grease on bushesReplace hub and/or main shaft
11CHECK ON FLYWHEEL CONDITIONAll OKProblems metOperation
Check the condition of the flywheel

In particular, check:

  • condition of surface
  • wear
  • chips
  • signs of overheating;
Continue to Step 12Flywheel damagedReplace the flywheel Op.   1024B10 
12CHECK ON CORRECT OPERATIONAll OKProblems metOperation
Check that the fault is no longer presentEnd of diagnosis.