22 · Diagnostics

Clutch does not release correctly

Make: Lancia
Model: Thesis Factory Service Manual
Year: 2002–2009
Section: Clutch › Clutch does not release correctly

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Fault diagnosisClutch does not release correctly

CLUTCH DOES NOT RELEASE CORRECTLY

2.0 TB, 2.4 20V, 2.4 JTD 10V, 2.4 JTD 20V

There is sticking or noise when changing lower gears or engaging reverse

STEP	OPERATIONS TO BE CARRIED OUT	TEST RESULTS
0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	With the engine idling, check whether the problem occurs in all gears Check whether the clutch pedal travel is correct	Move on to Step	1. It occurs in all gears	Move on to Step
		Move on to Step	2. Only when some gears are engaged	2. Continue following the instructions in Table C002 Continue following the instructions in the table C02 GEAR ENGAGEMENT OR RELEASE DIFFICULT/NOISY
1	VISUAL INSPECTION FOR LEAKS OR SEEPAGE	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check the fluid level in the reservoir Visually inspect the pipes - clutch Check that there are no leaks or damage Check for leaks from the bellhousing (clutch actuator area)	Move on to Step	1. No fluid	1. Top up the level
			2. Leaks, damage, seepage from the pipes and connectors	2. Repair the defective or damaged components
			3. Oil leaks from the clutch hydraulic actuator	3. Replace the clutch control actuator See in Op. 1820B38 CLUTCH HYDRAULIC ACTUATOR/OPERATING CYLINDER - R.R. and bleed air with clutch removed
2	CHECK FOR AIR IN THE CIRCUIT	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Operate the pedal and check if it is sufficiently flexible	Move on to Step	Pedal very flexible	Bleed the air
3	CLUTCH PUMP CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Press the clutch pedal, check that the travel and force are correct	Move on to Step	The pedal goes to the end of travel position without any resistance	Change pump See in Op. 1820B20 MASTER CYLINDER (pump) - R.R. and Bleed air
4	CLUTCH ASSEMBLY CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Visually inspect the condition of the clutch assembly, making sure that there are no breaks (pressure plate) or obvious deteriation (disc)	Move on to Step	Obvious deterioration of the clutch disc; pressure plate broken	Replace the assembly See in Op. 1810A20 CLUTCH - R.R.
5	CLUTCH SLIDING SPLINED HUB CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check: The condition of the clutch plate hub the condition of the main shaft hub	Move on to Step	1. Clutch plate hub worn	1. Replace the clutch plate See in Op. 1810A24 CLUTCH - R.R. with gearbox removed
		Move on to Step	2. Shaft damaged	2. Replace the main shaft See in Op. 2110B32 MANUAL GEARBOX (5 speed) and differential - Dismantling and Reassembly - Washing components - Replacing synchronizers, internal controls, shafts and bearings, if necessary
6	FLYWHEEL CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fitting clearance between the centering bush and the gearbox main shaft is correct	Move on to Step	Bush worn	Replace the flywheel See in Op. 1024B22 ENGINE FLYWHEEL - R.R. with clutch removed for versions with manual gearbox
7	CHECK ON CORRECT OPERATION	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check that the fault is no longer present

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Parts & tools for this job For 2002 Lancia Thesis

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