198001711 - E001 CLUTCH NOT RELEASING CORRECTLY

0PRELIMINARY CHECKSALL OKPROBLEMS ENCOUNTEREDACTION
Carry out a driving cycle simulating a hilly / urban route with frequent gear changes and 4-5 departures from a standstill to heat up the clutch/engine assemblies.Assess the manoeuvrability of the gearbox by carrying out the following with the vehicle stationary and the engine idling:- engagements of reverse gear with manoeuvre times increasing from 1 to 4 seconds;- engagements of forward speeds;- carry out the manoeuvres by fully depressing the clutch pedal to the end of travel position.- eliminate any obstacles to the correct clutch pedal travel (positioning of mats, interference of cables, etc.)Move on to Step 1The problem only occurs when certain speeds are engaged.Proceed as instructed in the    See table C002 GEAR ENGAGEMENT OR RELEASE DIFFICULT
1CLUTCH LEVER TRAVEL CHECKALL OKPROBLEMS ENCOUNTEREDACTION
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 9Clutch lever on gearbox travel incomplete.Move on to Step 2.
2VISUAL INSPECTION FOR LEAKS OR SEEPAGEALL OKPROBLEMS ENCOUNTEREDACTION
- Visually inspect the operating cylinder and pipes.- Check that there is no seepage, leaks or damage.Move on to Step 3Leaks, damage or seepage from pipes and/or hydraulic connectors.Repair the defective or damaged components.
3AIR IN HYDRAULIC CLUTCH CIRCUIT CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Using the operating cylinder bleed screw, check that there is no air in the circuit.Move on to Step 4Air in the circuit.Bleed the air    Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR
4CLUTCH CONTROL CYLINDER CHECK (ON VEHICLE)ALL OKPROBLEMS ENCOUNTEREDACTION
- Release the cylinder from the clutch control lever, keeping it connected to the hydraulic system.- Press the pedal, producing thrust pressure and check the push rod travel.- Using a drift, retract the push rod, checking that it travels freely.Move on to Step 5Clutch control cylinder malfunction.Remove the clutch control cylinder    Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R.and move on to Step 6.
5ENGINE AND GEARBOX CASING ALIGNMENT CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check for the centring pins on the engine block, checking whether the flexible couplings have become loose if the centring pins are not present.Move on to Step 6The centring pins are missing.Correct the problem by inserting the centring pins
The flexible couplings have become loose.Ensure the flexible couplings are correctly closed.
6CLUTCH CONTROL CYLINDER CHECK (WITH GEARBOX REMOVED)ALL OKPROBLEMS ENCOUNTEREDACTION
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 7Clutch control cylinder malfunction.Replace the clutch control cylinder    Op. 1820B38 CLUTCH HYDRAULIC ACTUATOR - R.R. AND BLEED AIR WITH GEARBOX REMOVED
7CLUTCH PEDAL TRAVEL CHECKALL OKPROBLEMS ENCOUNTEREDACTION
With the system disconnected, check that the travel is correct when the pedal is pressed and released.Move on to Step 8Hydraulic pump malfunctionReplace the pump    Op. 1820B20 MASTER CYLINDER (PUMP) - R + R
Hose from clutch reservoir to pump is worn or distorted.Replace the hose    Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R
Delivery hose to clutch control cylinder is worn or distorted.Replace the hose    Op. 1820B55 FLEXIBLE PIPE WITH OPERATING CYLINDER VIBRATION DAMPER - R.R.
8CLUTCH PEDAL CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Clutch pedal disconnected from transmission    Op. 3330B26 CLUTCH PEDAL - R+R check that it travels freely and there is no sticking or hardening.Move on to Step 9Clutch pedal clearance or hardening.Replace the pedal    Op. 3330B26 CLUTCH PEDAL - R+R
9PRESSURE PLATE LEVER AND BEARING CHECK (WITH GEARBOX REMOVED)ALL OKPROBLEMS ENCOUNTEREDACTION
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 pressure plate bearing slides freely in its housing and shows no signs of damage.move on to Step 10Dirt or wear due to insufficient greasing does not allow the pressure plate bearing to slide correctly.Replace the faulty or damaged components.
10CLUTCH ASSEMBLY CHECKALL OKPROBLEMS ENCOUNTEREDACTION
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 that there is no obvious deterioration of the driven disc or grease/oil on the friction surfaces.move on to Step 11Obvious deterioration of the clutch disc and/or pressure plate is broken.Replace the assembly    Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED
Oil or grease on the disc.Remove the oil or grease from the disc.
Flexible coupling springs weak or broken.Replace the mechanism    Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED
Break at the base of the clutch disc friction material support segments.Replace the clutch plate    Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED
11CLUTCH SLIDING SPLINED HUB CHECKALL OKPROBLEMS ENCOUNTEREDACTION
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 12Main shaft damaged.Replace the main shaft.
Hub worn.Replace the hub.
Excess grease on the bushes.Remove the excess grease from the bushes.
Gearbox shaft centring bush worn / half locked.Replace the bush
12CLUTCH SLIDING SPLINED HUB CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Check the condition of the flywheel.In particular, check:

  • the condition of the surface;

  • wear;

  • cuts;

  • presence of grease/oil on the disc surfaces;

  • signs of overheating.
End of diagnosisFlywheel damaged.Replace the flywheel    Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX
Presence of dust in the flywheel friction ringRemove the dust from the flywheel friction seal.