22 · Diagnostics

Gear engagement or release difficult

Make: Alfa Romeo
Model: 147 Factory Service Manual
Year: 2000–2004
Section: Gear shift › Gear engagement or release difficult

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Fault diagnosisGear engagement or release difficult

GEAR ENGAGEMENT OR RELEASE DIFFICULT

1.6 TS, 2.0 TS

The engagement of the gears is difficult; there is also noise in the gearbox area (the gearbox grates)

1	CLUTCH CHECK	All OK	Problems met	Operation
		Results of the tests
	Check that the clutch releases properly: with the engine running, press the clutch pedal and engage a gear	Continue to Step 3	The gearbox always grates in any gear: the clutch does not disengage	See table E01 CLUTCH NOT RELEASING CORRECTLY
2	CHECK ON ELECTROHYDRAULIC UNIT	All OK	Problems met	Operation
2.0 TS Cambio robotizzato	Using the diagnostic equipment, carry out the operations described See table C01 GEAR CONTROL HARDENINGSteps 4 - 5 - 6	Continue to Step 3	No problems are found in the electrohydraulic unit, the geabox noise persists.	Check the clutch assembly See table E01 CLUTCH NOT RELEASING CORRECTLYSteps 4 - 6 - 6
3	CHECK GEAR SELECTION	All OK	Problems met	Operation
	Check the condition of the pre-synchronizers	Continue to Step 4	Pre-synchronizers damaged	Replace the pre-synchronizers
4	CHECK ON SYNCHRONIZER RINGS	All OK	Problems met	Operation
	Overhaul the gearbox in accordance with the procedures; in particular check that the synchronizer rings are not worn on the internal surfaces	Continue to Step 5	Seals worn	Replace the synchronizers
5	CHECK GEARS	All OK	Problems met	Operation
	Overhaul the gearbox in accordance with the procedures, checking in particular the gear front teeth; they should not be excessively worn or chipped	Continue to Step 6	Gears worn	Replace the faulty gears
6	CHECK HUBS AND SLIDING SLEEVES	All OK	Problems met	Operation
	Overhaul the gearbox in accordance with the procedures and check that the hubs and sliding sleeves do not show wear or excessive play.	Continue to Step 7	Sleeves or hubs excessively worn	Replace worn parts
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

The engagement of the gears is difficult; there is also noise in the gearbox area (the gearbox grates)

1	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
		Results of the tests
	Connect the diagnostic equipment (Examiner or Examiner plus) to the diagnostic socket and check that there are no errors in the Selespeed control unit	Continue to Step 2	There are faults in the control unit	Continue following the instructions for the diagnostic equipment
2	ROAD TEST	All OK	Problems met	Operation
	Carry out a road test, checking the behaviour of the gearbox when engaging all the gears	Continue to Step 6	The gearbox grates in all gears	Continue to Step 3
		Continue to Step 6	The gearbox does not grate on all gears (only some of them)	Continue to Step 5
3	CHECKING WITH DIAGNOSTIC EQUIPMENT	All OK	Problems met	Operation
	Connect the diagnostic equipment (Examiner or Examiner plus) to the diagnostic socket and carry out: Clutch self-calibration Adjustment of clutch pushrod	Continue to Step 6	Fault persists	Continue to Step 4
4	CLUTCH PLATE CHECK	All OK	Problems met	Operation
	Verify: Condition of diaphragm spring on pressure plate Condition and correct sliding movement of clutch plate	Continue to Step 5	Fault in diaphragm spring	Replace clutch assembly Op. 1810A20
		Continue to Step 5	Fault in clutch plate	Replace clutch assembly Op. 1810A20
5	CHECK CONDITION OF GEARBOX	All OK	Problems met	Operation
	Check condition of internal components of gearbox	Continue to Step 6	Pre-synchronizers damaged	Gearbox overhaul Op. 2110B20
			Synchronizers damaged or worn	Gearbox overhaul Op. 2110B20
			Gears worn	Gearbox overhaul Op. 2110B20
			Sleeves or hubs worn	Gearbox overhaul Op. 2110B20
6	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'

1.9 JTD 8V

The engagement of the gears is difficult; there is also noise in the gearbox area (the gearbox grates)

1	CLUTCH CHECK	All OK	Problems met	Operation
		Results of the tests
	Check with the engine running and the car stopped that there is no noise (grating gearbox) when all the gears are engaged.	Continue to Step 2	The gearbox grates on all gears	See table E01
		Continue to Step 2	The gearbox does not grate on all the gears (only some of them)	Continue to Step 2
2	CHECK CONDITION OF GEARBOX	All OK	Problems met	Operation
	Check condition of gearbox internal components	Continue to Step 3	Pre-synchronizers damaged	Gearbox overhaul Op. 2110B20
			Synchronizers damaged or worn	Gearbox overhaul Op. 2110B20
			Gears worn	Gearbox overhaul Op. 2110B20
			Sleeves or hubs worn	Gearbox overhaul Op. 2110B20
3	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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