22 · Diagnostics

Clutch slipping

Make: Alfa Romeo
Model: GT Factory Service Manual
Year: 2003–2010
Section: Clutch › Clutch slipping

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Fault diagnosisClutch slipping

CLUTCH SLIPPING

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	Set off from a standstill in 4th gear, gradually releasing the clutch pedal and check the fault: the car does not move and the engine does not stall	Continue to Step 1	The engine cuts out: the clutch does not slip
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	CHECK ON CLUTCH PEDAL	All OK	Problems met	Operation
	After disconnecting the clutch pedal from the transmission, check that it travels freely without tight spots or stiffness	Continue to Step 3	Play or stiffness on clutch pedal	Replace the pedal Op. Op. 3330B26 CLUTCH PEDAL - R+R
3	CHECK SLIDING OF OPERATING CYLINDER PUSHROD	All OK	Problems met	Operation
	Check the travel and return to rest position of the clutch operating cylinder pushrod	Continue to Step 8	Incomplete travel of clutch control cylinder pushrod	Continue to Step 4
4	CLUTCH CONTROL LEVER CHECK	All OK	Problems met	Operation
	Release the clutch operating cylinder from the lever and check that it is free	Continue to Step 5	The lever is not free	Continue to Step 8
5	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 8	Malfunction of clutch control cylinder	Remove the clutch operating cylinder Op. Op. 1820B30 SLAVE CYLINDER - R + R Continue to Step 6
6	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 7	Malfunction of clutch control cylinder	Replace the clutch operating cylinder Op. Op. 1820B30 SLAVE CYLINDER - R + R
7	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 8	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
			Hose from clutch cylinder to hydraulic actuator worn or distorted	Replace the pipe Op. 1820B52
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

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Parts & tools for this job For 2003 Alfa Romeo GT

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