23 · Diagnostics

Clutch not releasing correctly

Make: Alfa Romeo
Model: 159 Factory Service Manual
Year: 2005–2011
Section: Clutch › Clutch not releasing correctly

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Fault diagnosisClutch not releasing correctly

CLUTCH NOT RELEASING CORRECTLY

0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	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
	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
	- 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
	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
	- 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
	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
		Move on to Step 6	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
	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
	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
	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
	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
	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
	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
	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
	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 diagnosis	Flywheel damaged.	Replace the flywheel Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX
		End of diagnosis	Presence of dust in the flywheel friction seal.	Remove the dust from the flywheel friction seal.

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Parts & tools for this job For 2005 Alfa Romeo 159

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