22 · Diagnostics

Clutch not releasing correctly

Make: Alfa Romeo
Model: 147 Factory Service Manual
Year: 2000–2004
Section: Clutch › Clutch not releasing correctly

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Fault diagnosisClutch not releasing correctly

CLUTCH NOT RELEASING CORRECTLY

1.6 TS

There is sticking or noise during low gear changes or when engaging reverse gear

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	With the engine idling, check whether the fault occurs in all gears Check the clutch pedal travel	Continue to Step 1	It occurs in all gears	Continue to Step 1
		Continue to Step 1	Only when engaging certain gears	See table C02
1	VISUAL CHECK FOR LEAKS	All OK	Problems met	Operation
	Visually inspect the pipes - clutch Check that there are no leaks or damage Check for leaks from the bell housing (clutch actuator area)	Continue to Step 2	Leaks, damage or seepage from the pipes and connectors	Renew the defetive or damaged components
		Continue to Step 2	Oil leaks from the hydraulic clutch actuator	Replace clutch operating actuator Op. 1820B38
2	CLUTCH PUMP CHECK	All OK	Problems met	Operation
	Press the clutch pedal and check that the travel and force are correct	Continue to Step 3	Force on the pedal slight, the fully reaches the end of travel position without any resistance	Replace the pump Op. 1820B20
3	CHECK FOR AIR IN THE SYSTEM	All OK	Problems met	Operation
	Operate the pedal and check whether it is excessively soft	Continue to Step 4	Pedal very soft	Bleed the air Op. 3330A14
4	CHECK ON CLUTCH ASSEMBLY	All OK	Problems met	Operation
	Visual check on the condition of the clutch assembly, which should not show breaks (pressure plate) and/or obvious deterioration (plate)	Continue to Step 5	Obvious deterioration of the clutch plate; pressure plate broken	Replace the assembly Op. 1810A20
5	CHECK ON CLUTCH SPLINED HUB	All OK	Problems met	Operation
	Verify: that there is no excess grease on the clutch plate hub bushes and the gearbox main shaft the condition of the main shaft hub	Continue to Step 6	Clutch plate hub worn	Replace the clutch plate Op. 1810A24
		Continue to Step 6	Shaft damaged	Replace the main shaft Op. 2110B32
6	FLYWHEEL CHECK	All OK	Problems met	Operation
	Check in particular: condition of clutch support surface wear, signs of overheating	Continue to Step 7	Flywheel damaged	Replace flywheel Op. 1024B32
7	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present		Fault persists	Search for the fault starting from another symptom'

2.0 TS

There is sticking or noise during low gear changes or when engaging reverse gear

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Road test the vehicle to check the operation of the gearbox, selecting all the gears manually.	Continue to Step 1	The fault is present in all gears	Continue to Step 1
		Continue to Step 1	The fault is only present when some gears are engaged	See table C02
1	VISUAL CHECK FOR LEAKS	All OK	Problems met	Operation
	Visually inspect the electro-hydraulic gear selection/engagement - clutch assembly and the bell housing (clutch actuator area)	Continue to Step 2	Leaks from pipes and hoses	Eliminate leaks and replace defective components following recommended procedures
2	CHECK ON CLUTCH ASSEMBLY	All OK	Problems met	Operation
	Visual check on the condition of the clutch assembly, which should not show breaks (pressure plate) and/or obvious deterioration (plate)	Continue to Step 3	Obvious deterioration of the clutch plate; pressure plate broken	Replace the assembly Op. 1810A28
3	CHECK ON CLUTCH SPLINED HUB	All OK	Problems met	Operation
	Verify: the condition of the clutch plate the condition of the main shaft hub In addition to the check described above, check that the thrust bearing control lever rotates freely	Continue to Step 4	Clutch plate hub worn / damaged	Replace the clutch plate Op. 1810A24
			Shaft damaged	Replace the main shaft Op. 2110B32
			Thrust bearing control lever seized	Replace lever bushes Op. 2110B20
4	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present		Fault persists	Search for the fault starting from another symptom'

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Parts & tools for this job For 2000 Alfa Romeo 147

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