323001261 - E002 CLUTCH SLIPPING

Test results
0PRELIMINARY CHECKSAll OKProblems encounteredOperation
- Carry out a driving cycle simulating a hilly/urban route with frequent gear changes to heat up the clutch/engine assemblies. Evaluate 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
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 71. Clutch lever on gearbox travel incomplete.2. Clutch pedal free travel insufficient1. Move on to Step 22. Move on to Step 2
2CLUTCH 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 3Clutch pedal clearance or hardeningReplace the pedal    Op. 3330B26 CLUTCH PEDAL - R+R
3OPERATING CYLINDER PUSH ROD SLIDING CHECKAll OKProblems encounteredOperation
Check the clutch operating cylinder push rod travel and return in the rest positionMove on to Step 7Clutch control cylinder push rod travel incompleteRelease the clutch control cylinder from the lever and check that the latter is freeIf it is free, move on to Step 4, otherwise move on to Step 7
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 freelyMove on to Step 7Clutch control cylinder malfunctionRemove the clutch control cylinder and move on to Step 5
5CLUTCH CONTROL CYLINDER CHECK (WITH GEARBOX REMOVED)All 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 6Clutch control cylinder malfunctionReplace the clutch control cylinder
6CLUTCH 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 71. Hydraulic pump malfunction.2. Hose from clutch reservoir to pump is worn or distorted.3. Delivery hose to clutch control cylinder is worn or distorted1. 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
7PRESSURE 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.The thrust bearing offset reference on the diaphragm spring may indicate that the centring is not correct.Move on to Step 81. The presence of dirt or wear due to insufficient greasing does not allow the thrust bearing to slide correctly.2. Thrust bearing not correctly centred.1. Replace the faulty or damaged components2. Ensure that the bearing is correctly centred
8CLUTCH 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 91. Obvious deterioration of the clutch plate and/or plate broken2. Clutch plate seal vitrified3. Oil or grease on the disc4. Diaphragm spring broken.1. Replace the assembly2. Replace the clutch plate3. Remove the oil or grease from the disc4. Replace the mechanism
9CLUTCH 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 10Main shaft damaged, hub worn, excess grease on the bushes.Replace the hub and/or main shaft
10FLYWHEEL 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 overheating.End of diagnosis1. Flywheel damaged2. Presence of dust in the flywheel friction seal.1. Replace the flywheel2. Remove the dust from the flywheel friction seal.