23 · Diagnostics

Clutch pedal hardening

Make: Alfa Romeo
Model: 159 Factory Service Manual
Year: 2005–2011
Section: Clutch › Clutch pedal hardening

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Fault diagnosisClutch pedal hardening

CLUTCH PEDAL HARDENING

0	PRELIMINARY CHECKS	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Check whether there is excessive resistance when the clutch pedal is pressed. N. B.: Since this symptom is "subjective", make sure that there is actually hardening compared with the previous so-called normal situation or compared with similar vehicles.	Move on to Step 1
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 3	Clutch lever on gearbox travel incomplete.	Move on to Step 2
2	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 3	Clutch pedal clearance or hardening.	Replace the pedal Op. 3330B26 CLUTCH PEDAL - R+R
3	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 4	Leaks, damage or seepage from pipes and/or hydraulic connectors.	Repair the defective or damaged components.
4	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 5	Air in the circuit.	Bleed the air Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR
5	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 7	Clutch control cylinder malfunction.	Remove the clutch control cylinder Op. 1820B30 CLUTCH HYDRAULIC ACTUATOR - R.R. and move on to Step 6
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. 1820B38 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL - R.R WITH GEARBOX REMOVED
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	1. Hydraulic pump malfunction	1. Replace the pump Op. 1820B20 MASTER CYLINDER (PUMP) - R + R
			2. Flexible pipe from clutch reservoir to pump worn or distorted.	2. Replace the pipe Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R
			3. Flexible supply pipe to clutch control cylinder worn or distorted.	3. Replace the pipe Op. 1820B56 RIGID PIPE FROM VIBRATION DAMPER TO SLAVE CYLINDER - R R
8	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 9	1. The presence of dirt or wear due to insufficient greasing does not allow the plate bearing to slide correctly.	1. Replace the faulty or damaged components.
		Move on to Step 9	2. Clutch release fork half casings worn/broken.	2. Replace the release fork half casings Op. 1820B38 HYDRAULIC CLUTCH ACTUATOR WITH COAXIAL CONTROL - R.R WITH GEARBOX REMOVED
9	CLUTCH ASSEMBLY CHECK	ALL OK	PROBLEMS ENCOUNTERED	ACTION
	Visually inspect the condition of the clutch assembly making sure it is not broken (pressure plate) and/or showing signs of obvious deterioration (disc). Measurements using the gauge as in the manual	Move on to Step 10	Obvious deterioration of the clutch disc and/or plate broken.	Replace the assembly Op. 1810A24 CLUTCH - R + R WITH GEARBOX REMOVED
10	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 11	Main shaft damaged, hub worn, excess grease on the bushes.	Replace the hub and/or main shaft.
11	FLYWHEEL CONDITION 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	1. Flywheel damaged.	1. Replace the flywheel Op. 1024B10 ENGINE FLYWHEEL - R + R FOR VERSIONS WITH MANUAL GEARBOX
		End of diagnosis	2. Presence of dust in the flywheel friction seal.	2. Remove the dust from the flywheel friction seal.

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Parts & tools for this job Staging For 2005 Alfa Romeo 159

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