| 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 and departures from a standstill, letting the engine and in particular the clutch reach operating temperature.
- Carry out departures from a standstill with the engine speed not below 1000 rpm, releasing the clutch pedal gradually, simulating the vehicle driving in traffic at a speed of around 10-20 km/h for a few seconds.
- Carry out departures at different engine speeds, hot and cold, at different gradients.
- Let the vehicle reach a constant speed (about 1000 rpm in 4th gear) and, with the clutch pedal released, accelerate quickly by fully depressing the accelerator pedal.
- Check for irregular feed (jerking).
| Move on to Step 1 | Presence of irregular feed (jerking) | Check that the engine mounts are properly secured. |
| 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 4 | 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 | ENGINE AND GEARBOX CASING ALIGNMENT CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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 4 | 1. The centring pins are missing. | 1. Correct the problem by inserting the centring pins |
| 2. The flexible couplings have become loose. | 2. Restore the correct closure. |
| 4 | 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 pressure plate bearing slides freely in its housing and shows no signs of damage. | Move on to Step 5 | The presence of dirt or wear due to insufficient greasing does not allow the pressure plate bearing to slide correctly. | Replace the faulty or damaged components. |
| 5 | CLUTCH ASSEMBLY CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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.Measurements using the gauge as in the manual. | Move on to Step 6 | 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. Disc distorted. | 2. Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 3. Plate with vitrified seal. | 3. Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 4. Oil or grease on the disc. | 4. Remove the oil or grease. |
| 5. Break at the base of the clutch disc friction material support segments. | 5. Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 6. Flexible coupling system seriously damaged. | 6. Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 6 | 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 7 | Main shaft damaged, hub worn, excess grease on the bushes. | Replace the hub and/or main shaft |
| 7 | 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 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. |