| 0 | PRELIMINARY CHECKS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check whether there is excessive resistance when the clutch pedal is pressed.N. B.: Since this symptom is "subjective", make sure that there is actually hardening compared with the previous so-called normal situation or compared with similar vehicles. | Move on to Step 1 | | |
| 1 | CLUTCH LEVER TRAVEL CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check, inside the engine compartment, that when the clutch pedal is pressed the clutch control lever on the gearbox completes the correct travel. | Move on to Step 3 | Clutch lever on gearbox travel incomplete. | Move on to Step 2 |
| 2 | CLUTCH PEDAL CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Clutch pedal disconnected from transmission Op. 3330B26 CLUTCH PEDAL - R+Rcheck that the travel is free and there is no sticking or hardening. | Move on to Step 3 | Clutch pedal clearance or hardening. | Replace the pedal Op. 3330B26 CLUTCH PEDAL - R+R |
| 3 | VISUAL INSPECTION FOR LEAKS OR SEEPAGE | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| - Visually inspect the operating cylinder and pipes.
- Check that there is no seepage, leaks or damage.
| Move on to Step 4 | Leaks, damage or seepage from pipes and/or hydraulic connectors. | Repair the defective or damaged components. |
| 4 | CHECK FOR AIR IN THE HYDRAULIC CLUTCH CIRCUIT | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Using the operating cylinder bleed screw, check that there is no air in the circuit. | Move on to Step 5 | Air in the circuit. | Bleed the air Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR |
| 5 | CLUTCH CONTROL CYLINDER CHECK (ON VEHICLE) | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| - Release the cylinder from the clutch control lever, keeping it connected to the hydraulic system.
- Press the pedal producing the thrust pressure and check the push rod travel.
- Using a drift, retract the push rod checking that it travels freely.
| Move on to Step 7 | Clutch control cylinder malfunction. | Remove the clutch control cylinder Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R.and move on to Step 6 |
| 6 | CLUTCH CONTROL CYLINDER CHECK (WITH GEARBOX REMOVED) | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| With the part at the bench, apply pressure (using compressed air) and check the push rod travel (the test mirrors what was done in the vehicle).N.B.: This test is designed to ensure that the problem is due to the cylinder and not to the pipes or the pump. | Move on to Step 7 | Clutch control cylinder malfunction. | Replace the clutch control cylinder Op. 1820B38 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL - R.R WITH GEARBOX REMOVED |
| 7 | CLUTCH PEDAL TRAVEL CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| With the system disconnected, check that the travel is correct when the pedal is pressed and released. | Move on to Step 8 | 1. Hydraulic pump malfunction | 1. Replace the pump Op. 1820B20 MASTER CYLINDER (PUMP) - R + R |
| 2. Flexible pipe from clutch reservoir to pump worn or distorted. | 2. Replace the pipe Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R |
| 3. Flexible supply pipe to clutch control cylinder worn or distorted. | 3. Replace the pipe Op. 1820B52 HOSE FROM MASTER CYLINDER (PUMP TO CLUTCH HYDRAULIC ACTUATOR - R + R |
| 8 | PLATE LEVER AND BEARING CHECK (WITH GEARBOX REMOVED) | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| After the gearbox has been removed, check that there is no hardening of the lever (as a result of dirt or insufficient greasing) and that the plate bearing slides freely in its housing and shows no signs of damage. | Move on to Step 9 | 1. The presence of dirt or wear due to insufficient greasing does not allow the plate bearing to slide correctly. | 1. Replace the faulty or damaged components. |
| 2. Clutch release fork half casings worn/broken. | 2. Replace the release fork half casings Op. 1820B38 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL - R.R WITH GEARBOX REMOVED |
| 9 | CLUTCH ASSEMBLY CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Visually inspect the condition of the clutch assembly making sure it is not broken (pressure plate) and/or showing signs of obvious deterioration (disc). Measurements using the gauge as in the manual | Move on to Step 10 | Obvious deterioration of the clutch disc and/or plate broken. | Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 10 | CLUTCH SLIDING SPLINED HUB CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| 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 hub.
| Move on to Step 11 | Main shaft damaged, hub worn, excess grease on the bushes. | Replace the hub and/or main shaft. |
| 11 | FLYWHEEL CONDITION CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
|---|
| Check the condition of the flywheel.In particular, check:- the state of the surface;
- presence of grease/oil on the disc surfaces;
| End of diagnosis | 1. Flywheel damaged. | 1. Replace the flywheel Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX |
| 2. Presence of dust in the flywheel friction seal. | 2. Remove the dust from the flywheel friction seal. |