| 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 whether there is irregular advance (jerking).
| Move on to Step 1 | Presence of irregular advance (jerking) | Check that the engine supports 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 play 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 the travel is free 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 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 4 | 1. The centering pins are missing. | 1. Correct the problem by inserting the centering pins |
| 2. The flexible couplings have become loose. | 2. Restore the correct closure. |
| 4 | 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 5 | 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. |
| 5 | 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.Measurements using the gauge as in the manual. | Move on to Step 6 | 1.Obvious deterioration of the clutch disc and/or plate broken. | 1. Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 2. Disc distorted. | 2. Replace the clutch plate Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 3. Plate with vitrified seal. | 3. Replace the clutch plate 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 clutch plate Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 6. Flexible coupling system seriously damaged. | 6. Replace the mechanism Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED |
| 5 | 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.Measurements using the gauge as in the manual. | Move on to Step 6 | 1.Obvious deterioration of the clutch disc and/or plate 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 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 state 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 seal. | 2. Remove the dust from the flywheel friction seal. |