23 · Diagnostics

Clutch not releasing correctly

Make: Fiat
Model: Panda Factory Service Manual
Year: 2003–2012
Section: Clutch › Clutch not releasing correctly

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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.	Coolant leaks detected See table C02
1	CHECK ON CLUTCH LEVER TRAVEL	All OK	Problems met	Operation
	Check, inside the engine compartment, that when the clutch pedal is pressed, the clutch control lever on the gearbox performs the 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 Continue to Step 4
4	CHECK ON CLUTCH CONTROL SYSTEM (ON CAR)	All OK	Problems met	Operation
	Release the cylinder from the clutch control lever, 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. 1820B30 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. 1820B30
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. 1820B20
			Hose from clutch reservoir to pump worn or deformed	Replace the pipe Op. 1820B40
			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. 3330B26
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 caused by insufficient lubrication does not allow the clutch release bearing to slide correctly	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. 1810A24
10	CHECK ON SPLINED CLUTCH HUB	All OK	Problems met	Operation
	Check, in order: that there is no excess grease on the clutch plate hub bushes and the 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	CHECK ON FLYWHEEL CONDITION	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. 1024B10
12	Continue as instructed by the tester	All OK	Problems met	Operation
	Check that the fault is no longer present	End of diagnosis

‹ Prev Cruise control not working under any conditions Next › Clutch slipping

Parts & tools for this job Staging For 2003 Fiat Panda

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