| 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 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 1 | The problem only occurs when certain speeds are engaged. | Proceed as instructed in the See table C002 GEAR ENGAGEMENT OR RELEASE DIFFICULT |
| 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 9 | Clutch lever on gearbox travel incomplete. | Move on to Step 2. |
| 2 | VISUAL INSPECTION FOR LEAKS OR SEEPAGE | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| - Visually inspect the operating cylinder and pipes.- Check that there is no seepage, leaks or damage. | Move on to Step 3 | Leaks, damage or seepage from pipes and/or hydraulic connectors. | Repair the defective or damaged components. |
| 3 | CHECK FOR AIR IN THE HYDRAULIC CLUTCH CIRCUIT | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Using the operating cylinder bleed screw, check that there is no air in the circuit. | Move on to Step 4 | Air in the circuit. | Bleed the air Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR |
| 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 the thrust pressure and check the push rod travel.- Using a drift, retract the push rod checking that it travels freely. | Move on to Step 5 | Clutch control cylinder malfunction. | Remove the clutch control cylinder Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R.and move on to Step 6. |
| 5 | ENGINE AND GEARBOX CASING ALIGNMENT CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check for the centering pins on the engine block checking whether the flexible couplings have become loose if the centering pins are not present. | Move on to Step 6 | The centering pins are missing. | Correct the problem by inserting the centering pins |
| The flexible couplings have become loose. | Ensure the flexible couplings are correctly closed. |
| 6 | 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 7 | Clutch control cylinder malfunction. | Replace the clutch control cylinder Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R. |
| 7 | 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 8 | Hydraulic pump malfunction | Replace the pump Op. 1820B20 MASTER CYLINDER (PUMP) - R + R |
| Flexible pipe from clutch reservoir to pump worn or distorted. | Replace the pipe Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R |
| Flexible supply pipe to clutch control cylinder worn or distorted. | Replace the pipe Op. 1820B56 RIGID PIPE FROM VIBRATION DAMPER TO SLAVE CYLINDER - R R |
| 8 | 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 the travel is free and there is no sticking or hardening. | Move on to Step 9 | Clutch pedal clearance or hardening. | Replace the pedal Op. 3330B26 CLUTCH PEDAL - R+R |
| 9 | 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. | move on to Step 10 | The presence of dirt or wear due to insufficient greasing does not allow the plate bearing to slide correctly. | Replace the faulty or damaged components. |
| 10 | CLUTCH ASSEMBLY CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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 disc or grease/oil on the friction surfaces. | move on to Step 11 | Obvious deterioration of the clutch disc and/or plate 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 |
| 10 | CLUTCH ASSEMBLY CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| 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 disc or grease/oil on the friction surfaces. | move on to Step 11 | Obvious deterioration of the clutch disc and/or plate 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 assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| Break at the base of the clutch disc friction material support segments. | Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 11 | 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 hub. | move on to Step 12 | Main 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 centering bush worn / half locked. | Replace the bush |
| 12 | CLUTCH SLIDING SPLINED HUB CHECK | ALL OK | PROBLEMS ENCOUNTERED | ACTION |
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| Check the condition of the flywheel.In particular, check:- the state of the surface;
- presence of grease/oil on the disc surfaces;
| End of diagnosis | Flywheel damaged. | Replace the flywheel Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX |
| Presence of dust in the flywheel friction seal. | Remove the dust from the flywheel friction seal. |