- 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;

- engagement of forward gears: 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.)

Continue as instructed,

See table C002 GEAR ENGAGEMENT OR RELEASE DIFFICULT

- Visually inspect the operating cylinder and pipes.

- Check that there is no seepage, leaks or damage.

- 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.

1. The centering pins are missing.

2. The flexible couplings have become loose.

1. Correct the problem by inserting the centering pins

2. Ensure the flexible couplings are correctly closed.

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.

1. Hydraulic pump malfunction.

2. Flexible pipe from clutch reservoir to pump worn or distorted.

3. Flexible supply pipe to clutch control cylinder worn or distorted.

1. Replace the pump

Op. 1820B20 MASTER CYLINDER (PUMP) - R + R

2. Replace the pipe

Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R

3. Replace the pipe

Op. 1820B48 SUPPLY HOSE TO OPERATING CYLINDER - R.R.

Clutch pedal disconnected from transmission,

Op. 3330B26 CLUTCH PEDAL - R+R

check that the travel is free and there is no sticking or hardening.

Replace the pedal

Op. 3330B26 CLUTCH PEDAL - R+R

For the 1.2 8v, 1.4 8v, 1.3 JTD;

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.

Measurements using the gauge as in the manual.

1. Obvious deterioration of the clutch disc and/or plate broken.

2. Oil or grease on the disc.

3. Flexible coupling springs weak or broken.

4. Break at the base of the clutch disc friction material support segments.

1. Replace the assembly

2. Remove the oil or grease from the disc

3. Replace the mechanism

4. Replace the clutch plate

For the 1.9 JTD;

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.

Measurements using the gauge as in the manual.

1. Obvious deterioration of the clutch disc and/or plate broken.

2. Oil or grease on the disc.

3. Flexible coupling springs weak or broken.

4. Break at the base of the clutch disc friction material support segments.

1. Replace the assembly

2. Remove the oil or grease from the disc

3. Replace the mechanism

4. Replace the clutch plate

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.

1. Main shaft damaged.

2. Hub worn.

3. Excess grease on the bushes.

1. Replace the main shaft.

2. Replace the hub.

3. Remove the excess grease from the bushes

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

1. Flywheel damaged

2. Presence of dust in the flywheel friction seal

1. Replace the flywheel

2. Remove the dust from the flywheel friction seal