939003589 - E010 CLUTCH PEDAL HARDENING

0PRELIMINARY CHECKSALL OKPROBLEMS ENCOUNTEREDACTION
Check whether there is excessive resistance when the clutch pedal is pressed.N. B.: Since this symptom is "subjective", make sure that there is actually hardening compared with the previous so-called normal situation or compared with similar vehicles.Move on to Step 1
1CLUTCH LEVER TRAVEL CHECKALL OKPROBLEMS ENCOUNTEREDACTION
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 3Clutch lever on gearbox travel incomplete.Move on to Step 2
2CLUTCH PEDAL CHECKALL OKPROBLEMS ENCOUNTEREDACTION
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 3Clutch pedal clearance or hardening.Replace the pedal    Op. 3330B26 CLUTCH PEDAL - R+R
3VISUAL INSPECTION FOR LEAKS OR SEEPAGEALL OKPROBLEMS ENCOUNTEREDACTION

  • Visually inspect the operating cylinder and pipes.

  • Check that there is no seepage, leaks or damage.
Move on to Step 4Leaks, damage or seepage from pipes and/or hydraulic connectors.Repair the defective or damaged components.
4CHECK FOR AIR IN THE HYDRAULIC CLUTCH CIRCUITALL OKPROBLEMS ENCOUNTEREDACTION
Using the operating cylinder bleed screw, check that there is no air in the circuit.Move on to Step 5Air in the circuit.Bleed the air    Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR
5CLUTCH CONTROL CYLINDER CHECK (ON VEHICLE)ALL OKPROBLEMS ENCOUNTEREDACTION

  • 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 7Clutch control cylinder malfunction.Remove the clutch control cylinder    Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R.and move on to Step 6
6CLUTCH CONTROL CYLINDER CHECK (WITH GEARBOX REMOVED)ALL OKPROBLEMS ENCOUNTEREDACTION
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 malfunction.Replace the clutch control cylinder    Op. 1820B38 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL - R.R WITH GEARBOX REMOVED
7CLUTCH PEDAL TRAVEL CHECKALL OKPROBLEMS ENCOUNTEREDACTION
With the system disconnected, check that the travel is correct when the pedal is pressed and released.Move on to Step 81. Hydraulic pump malfunction1. Replace the pump    Op. 1820B20 MASTER CYLINDER (PUMP) - R + R
2. Flexible pipe from clutch reservoir to pump worn or distorted.2. Replace the pipe    Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R
3. Flexible supply pipe to clutch control cylinder worn or distorted.3. Replace the pipe    Op. 1820B56 RIGID PIPE FROM VIBRATION DAMPER TO SLAVE CYLINDER - R R
8PLATE LEVER AND BEARING CHECK (WITH GEARBOX REMOVED)ALL OKPROBLEMS ENCOUNTEREDACTION
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 91. The presence of dirt or wear due to insufficient greasing does not allow the plate bearing to slide correctly.1. Replace the faulty or damaged components.
2. Clutch release fork half casings worn/broken.2. Replace the release fork half casings    Op. 1820B38 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL - R.R WITH GEARBOX REMOVED
9CLUTCH ASSEMBLY CHECKALL OKPROBLEMS ENCOUNTEREDACTION
Visually inspect the condition of the clutch assembly making sure it is not broken (pressure plate) and/or showing signs of obvious deterioration (disc). Measurements using the gauge as in the manualMove on to Step 10Obvious deterioration of the clutch disc and/or plate broken.Replace the assembly    Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED
10CLUTCH SLIDING SPLINED HUB CHECKALL OKPROBLEMS ENCOUNTEREDACTION
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 11Main shaft damaged, hub worn, excess grease on the bushes.Replace the hub and/or main shaft.
11FLYWHEEL CONDITION CHECKALL OKPROBLEMS ENCOUNTEREDACTION
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 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.