22 · Diagnostics

Clutch not releasing correctly

Make: Alfa Romeo
Model: GT Factory Service Manual
Year: 2003–2010
Section: Clutch › Clutch not releasing correctly

‹ Prev The cruise control set- control is not working Next › Clutch slipping

Fault diagnosisClutch not releasing correctly

CLUTCH NOT RELEASING CORRECTLY

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	With the engine idling, check whether the fault is present when all gears are engaged. Eliminate any obstacles preventing the correct travel of the clutch pedal (position of mats, cable interference, etc.).	Continue to Step 1	The fault occurs only when some gears are engaged.	Continue according to the instructions in See table See table C02 GEAR ENGAGEMENT OR RELEASE DIFFICULT
1	CHECK ON CLUTCH LEVER TRAVEL	All OK	Problems met	Operation
	Check, in the engine compartment, that when the clutch pedal is pressed, the clutch control lever on the gearbox carries out its correct travel.	Continue to Step 8	Incomplete travel of clutch lever on gearbox	Continue to Step 2
2	VISUAL CHECK FOR LEAKS	All OK	Problems met	Operation
	Carry out a visual inspection of the operating cylinder and pipes Check that there are no leaks or damage	Continue to Step 3	Leaks or damage on pipes and/or hydraulic connections	Renew damaged or faulty components.
3	CHECK FOR PRESENCE OF AIR IN CLUTCH HYDRAULIC SYSTEM	All OK	Problems met	Operation
	Adjust the bleed screw on the operating cylinder to check that the system is free of air	Continue to Step 4	Presence of air in the hydraulic system	Bleed the air Op. Op. 0010T67 HYDRAULIC CLUTCH SYSTEM BLEED AIR Continue to Step 4
4	CHECK ON CLUTCH CONTROL SYSTEM (ON CAR)	All OK	Problems met	Operation
	Disengage the cylinder from the clutch control lever, although keeping it connected to the hydraulic system. Press the pedal to induce the thrust pressure and check the pushrod travel Push the pushrod back in using a punch, checking that it travels freely	Continue to Step 5	Malfunction of clutch control cylinder	Remove the clutch operating cylinder Op. Op. 1820B30 SLAVE CYLINDER - R + R Continue to Step 5
5	CHECK ON CLUTCH CONTROL CYLINDER (WITH GEARBOX REMOVED)	All OK	Problems met	Operation
	With the part at the bench, apply pressure (with compressed air) and check the pushrod travel (The test mirrors what was done on the car) The purpose of this test is to make sure that the fault is in the cylinder and not the pipes or pump	Continue to Step 6	Malfunction of clutch control cylinder	Replace the clutch operating cylinder Op. Op. 1820B30 SLAVE CYLINDER - R + R
6	CHECK ON CLUTCH PEDAL TRAVEL	All OK	Problems met	Operation
	With the system disconnected, check that the travel is correct when the pedal is pressed and released	Continue to Step 7	Malfunction of hydraulic pump	Replace the pump Op. Op. 1820B20 MASTER CYLINDER (PUMP) - R + R
			Hose from clutch reservoir to pump worn or deformed	Replace the pipe Op. Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R
			Supply hose to clutch operating cylinder worn or deformed	Replace the pipe Op. 1820B48
7	CHECK ON CLUTCH PEDAL	All OK	Problems met	Operation
	After disconnecting the clutch pedal from the transmission check that it travels freely with no stiffness or tight spots	Continue to Step 8	Play or stiffness on clutch pedal	Replace the pedal Op. Op. 3330B26 CLUTCH PEDAL - R+R
8	CHECK ON CLUTCH RELEASE LEVER AND BEARING (WITH GEARBOX REMOVED)	All OK	Problems met	Operation
	After removing the gearbox, check that the lever is not stiff (because of dirty or insufficient lubrication) and that the clutch release bearing runs freely in its seating and shows no signs of damage	Continue to Step 9	The presence of dirt or wear because of insufficient lubrication will not allow the clutch release bearing to slide properly	Replace the faulty or damaged parts
9	CHECK ON CLUTCH ASSEMBLY	All OK	Problems met	Operation
	Visual check on the condition of the clutch assembly, on which there should be no breaks (pressure plate) and/or obvious damage (driven plate) Measurements with gauge as per manual	Continue to Step 10	Obvious damage of clutch disc and/or breakage of pressure plate	Replace the assembly Op. Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED
10	CHECK ON SPLINED CLUTCH HUB	All OK	Problems met	Operation
	Check, in order: that there is not excessive grease on the bushes of the clutch disc hub and gearbox main shaft; Condition of hub and main shaft	Continue to Step 11	Main shaft damaged, hub worn, excessive grease on bushes	Replace hub and/or main shaft
11	FLYWHEEL CONDITION CHECK	All OK	Problems met	Operation
	Check the condition of the flywheel. In particular, check: condition of surface wear; chips; signs of overheating	Continue to Step 12	Flywheel damaged	Replace the flywheel Op. Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX
12	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis

‹ Prev The cruise control set- control is not working Next › Clutch slipping

Parts & tools for this job For 2003 Alfa Romeo GT

Links open Amazon search results in a new tab. As an Amazon Associate I earn from qualifying purchases.