323001260 - E001 CLUTCH NOT RELEASING CORRECTLY

Test results
0PRELIMINARY CHECKSAll OKProblems encounteredOperation
- 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;- engagement of forward gears: 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 engagedProceed as instructed,    See table C002 GEAR ENGAGEMENT OR RELEASE DIFFICULT
1CLUTCH LEVER TRAVEL CHECKAll OKProblems encounteredOperation
Check, inside the engine compartment, that when the clutch pedal is pressed the clutch control lever on the gearbox completes the correct travelMove on to Step 9Clutch lever on gearbox travel incompleteMove on to Step 2
2VISUAL INSPECTION FOR LEAKS OR SEEPAGEAll OKProblems encounteredOperation
- 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 connectorsRepair the defective or damaged components
3CHECK FOR AIR IN THE HYDRAULIC CLUTCH CIRCUITAll OKProblems encounteredOperation
Using the operating cylinder bleed screw, check that there is no air in the circuitMove on to Step 4Air in the circuitBleed the air
4CLUTCH CONTROL CYLINDER CHECK (ON VEHICLE)All OKProblems encounteredOperation
- 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 malfunctionRemove the clutch control cylinder and move on to Step 6
5ENGINE AND GEARBOX CASING ALIGNMENT CHECKAll OKProblems encounteredOperation
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 61. The centring pins are missing.2. The flexible couplings have become loose.1. Correct the problem by inserting the centring pins2. Ensure the flexible couplings are correctly closed.
6CHECKAll OKProblems encounteredOperation
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 malfunctionReplace the clutch control cylinder
7CLUTCH PEDAL TRAVEL CHECKAll OKProblems encounteredOperation
With the system disconnected, check that the travel is correct when the pedal is pressed and releasedMove on to Step 81. Hydraulic pump malfunction.2. Hose from clutch reservoir to pump is worn or distorted.3. Delivery hose to clutch control cylinder is worn or distorted.1. Replace the pump    Op. 1820B20 MASTER CYLINDER (PUMP) - R + R 2. Replace the hose    Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R 3. Replace the hose    Op. 1820B48 SUPPLY HOSE TO OPERATING CYLINDER - R.R.
8CLUTCH PEDAL CHECKAll OKProblems encounteredOperation
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 hardeningReplace the pedal    Op. 3330B26 CLUTCH PEDAL - R+R
9PRESSURE PLATE LEVER AND BEARING CHECK (WITH GEARBOX REMOVED)All OKProblems encounteredOperation
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 10The presence of dirt or wear due to insufficient greasing does not allow the plate bearing to slide correctlyReplace the faulty or damaged components
10CLUTCH ASSEMBLY CHECKAll OKProblems encounteredOperation
Visually inspect the state of the clutch assembly, making sure there are no breaks and/or signs of overheating on the plate, obvious deterioration of the driven plate or grease/oil on the friction surfaces.Measurements using the gauge as in the manual.Move on to Step 111. Obvious deterioration of the clutch plate and/or pressure plate broken.2. Oil or grease on the disc.3. Flexible coupling springs weak or broken.4. Break at the base of the clutch disc friction material support segments.1. Replace the assembly2. Remove the oil or grease from the disc3. Replace the mechanism4. Replace the clutch plate
11CLUTCH SLIDING SPLINED HUB CHECKAll OKProblems encounteredOperation
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 121. Main shaft damaged.2. Hub worn.3. Excess grease on the bushes.1. Replace the main shaft.2. Replace the hub.3. Remove the excess grease from the bushes
12FLYWHEEL CONDITION CHECKAll OKProblems encounteredOperation
Check the condition of the flywheel. In particular, check:- the state of the surface;- wear;- cuts;- presence of grease/oil on the disc surfaces;- signs of overheatingEnd of diagnosis1. Flywheel damaged2. Presence of dust in the flywheel friction seal1. Replace the flywheel2. Remove the dust from the flywheel friction seal