| 0 | PRELIMINARY CHECKS | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| - Carry out a driving cycle simulating a hilly/urban route with frequent gear changes to heat up the clutch/engine assemblies.
Assess the problem in the following usage conditions:- with the vehicle speed constant in 3rd-4th speed and the engine speed about 4-5 revs max torque, accelerate the engine rapidly with the accelerator pedal fully depressed.
- carry out departures from a standstill on a flat surface re-engaging the clutch and accelerating gradually from an initial engine speed of 1000-1500 rpm.
Carry out a departure from stationary in 4th gear, releasing the clutch pedal gradually and checking for the fault: the vehicle does not move and the engine does not cut out. | Move on to Step 1 | | |
| 1 | CLUTCH LEVER TRAVEL CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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 7 | 1. Clutch lever on gearbox travel incomplete. | 1. Move on to Step 2 |
| 2. Clutch pedal free travel insufficient. | 2. Move on to Step 2 |
| 2 | CLUTCH PEDAL CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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 3 | Clutch pedal clearance or hardening. | Replace the pedal Op. 3330B26 CLUTCH PEDAL - R+R |
| 3 | OPERATING CYLINDER PUSH ROD SLIDING CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check the clutch operating cylinder push rod travel and return in the rest position Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R. | Move on to Step 7 | Clutch control cylinder push rod travel incomplete. | Release the clutch control cylinder from the lever and check that the latter is free Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R.If it is free, move on to Step 4, otherwise move on to Step 7 |
| 4 | CLUTCH CONTROL CYLINDER CHECK (ON VEHICLE) | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| - 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 7 | Clutch control cylinder malfunction. | Remove the clutch control cylinder Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R.and move on to Step 5. |
| 5 | CLUTCH CONTROL CYLINDER CHECK (WITH GEARBOX REMOVED) | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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 6 | Clutch control cylinder malfunction. | Replace the clutch control cylinder Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R. |
| 6 | CLUTCH PEDAL TRAVEL CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| With the system disconnected, check that the travel is correct when the pedal is pressed and released. | Move on to Step 7 | 1. Hydraulic pump malfunction. | 1. Replace the pump Op. 1820B20 MASTER CYLINDER (PUMP) - R + R |
| 2. Hose from clutch reservoir to pump is worn or distorted. | 2. Replace the hose Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R |
| 3. Delivery hose to clutch control cylinder is worn or distorted. | 3. Replace the hose Op. 1820B55 FLEXIBLE PIPE WITH OPERATING CYLINDER VIBRATION DAMPER - R.R. |
| 7 | PRESSURE PLATE LEVER AND BEARING CHECK (WITH GEARBOX REMOVED) | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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.The thrust bearing offset mark on the diaphragm spring may indicate that the centring is not correct. | Move on to Step 8 | 1. The presence of dirt or wear due to insufficient greasing does not allow the thrust bearing to slide correctly. | 1. Replace the faulty or damaged components. |
| 2. Thrust bearing not correctly centred. | 2. Ensure that the bearing is correctly centred. |
| 8 | CLUTCH ASSEMBLY CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Visually inspect the condition of the clutch assembly, making sure there are no breaks and/or signs of overheating on the pressure plate, no obvious deterioration of the driven disc or grease/oil on the friction surfaces.Measurements using the gauge as in the manual. | Move on to Step 9 | 1. Obvious deterioration of the clutch disc and/or pressure plate is broken. | 1. Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 2. Clutch plate with vitrified seal. | 2. Replace the clutch plate Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 3. Oil or grease on the disc. | 3. Replace the assembly |
| 4. Diaphragm spring broken. | 4. Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 9 | CLUTCH SLIDING SPLINED HUB CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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 10 | Main shaft damaged, hub worn, excess grease on the bushes. | Replace the hub and/or main shaft. |
| 10 | FLYWHEEL CONDITION CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check the condition of the flywheel.In particular, check:- the condition 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 ring. | 2. Remove the dust from the flywheel friction seal. |