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Technical Clutch problems...

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Technical Clutch problems...

BikeDoc

BikeDoc

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Hi folks!
Not visited for a while, been busy, had PC problems, and my Multipla (02 115 JTD) has been behaving itself (apart from a few minor electrical niggles :rolleyes:).

Then yesterday, as I'd just reversed into a parking space, I couldn't get it out of gear.
Clutch pedal had very little resistance, no more than that of the pedal spring really, whereas it's usually quite 'heavy'.

Got a tow home, and started searching...
Thought the clutch line might just need bleeding, but the rattling noises when the clutch pedal was depressed (I know how it feels :() suggested that something more serious was up.
I'm fairly sure it's the release bearing gone, as I bled the line, and the travel of the slave piston is 'normal'.
The clutch arm has no resistance until right at the end of it's travel.

I have the gearbox disconnected now, but need to drop the subframe to get it right out.
I've been referring to SillyBilly's guide, very helpful.
https://sites.google.com/site/fiatmultipla/Home/repairs
And also the 'Changing a clutch in a Multi' guide, don't know the author...
Without them, I would have wasted time taking a few more bits and pieces off than needed, and would have taken a while to find some of the 'hidden' bolts, so thanks for that.:worship:

Engine and detached gearbox are currently hanging on straps from my home-made wooden support beam.
Wish me luck for tomorrow (y)

If anyone wants/needs pictures of anything specific while I have it apart, please feel free to ask.
 
I put my gearbox back in yesterday, after a clutch/flywheel job. Today I'm mounting the subframe, and starting on all the small pieces. I had to wait 1,5 week on the flywheel after taking everything apart, so I'm very curious if I remember how to put everything back in. Fingers crossed!

A few tips: Be careful with the IC when removing the gearbox. I found that some of the AC-pipe work was in the way for the clutch arm when taking the box in/out, but it worked. When putting the box back in I put a big allen key between the clutch arm and the gear box to prevent the arm from being pushed all the way in. That could have misplaced the release bearing. Somehow I don't feel like doing this job again... ;)

Good luck!
 
Well it's off and on the floor now, not a pretty sight inside...
Clutch1a.jpg


Clutch looks OK apart from some light wear marks on the spring fingers...
Clutch1.jpg


My Engine/Gearbox support beam...
Beam1a.jpg

The side pieces are bored to locate over the wing mount Allen screw heads, stopping the whole thing slipping forwards.

Just got to get a lift down to my local Allparts branch, they have a release bearing waiting for me, £20-ish.

For anyone following the guide, the 15mm headed subframe bolts don't need touching (other than the two that secure the steering rack).
Only the two 20mm headed ones at the ends of the beam, and the 18mm ones behind the suspension struts need to come out.
 
Do you not feel you should also swap the driven & cover plates while you have it in bits, regardless of how they look?
 
The Clutch assembly?
Want to avoid that if possible, it was replaced before we got the car, so should have plenty of life left in it still.
I'll probably remove it to make sure though.

Anyone know the wear limits, or where to find them?
Also, does anyone know the movement limit on the flywheel?
Mine's around 14-15mm.
 
From a recent thread (Credit to Unclechuchu)

Max. Clearance Angle [Degree] 20
Max. Sideplay [mm] 2,9s
 
As momoe says your flywheel is within limits. But there's quite a lot oil in there? Are you changing the seal as well?

I just put mine back together, and took her for a drive. Feels sooooooo nice to start her up after such a big job! I never changed a clutch before, so it feels extra nice. ;)
 
That's good to hear about the tolerances on the flywheel, thanks for that info. (y)

I will replace the seal while it's out, and the driveshaft one as well.
Silly not to for what little they cost.

Took the Clutch off, no discernible wear on the metal plates, but I'm not sure about the friction plate...
 
Decided to go for the sensible option and get a new clutch as well.
Was picking up the two oil seals from my local Fiat dealer (13 quid for the two), and just for a laugh, I asked them the price of a new clutch :rolleyes:
137 plus VAT, and 30 quid back on the old unit :D

Got it all back together yesterday, and when I pressed the clutch pedal down for the first time my heart sank, it felt just the same as when the bearing was gone, virtually no resistance :cry:
I started the engine and tried to put it in gear...and it just slipped right in with no resistance at all (y)

It's so light I can hardly feel it. whereas before it made my leg ache holding it down!
 
By the way, found the perfect point for suspending the gearbox...
GearboxSlingpoint.jpg

Between the Slave Cylinder r/h mounting point and the 'spare' threaded boss next to it.
Hangs perfectly level from this point.
 
Just replaced clutch and gear box on my multi but can now only select 1-3-5 gears. is there any form of adjustment or sequence I need to carry out to be able to select all gears Thanks
 
Hi there,

I changed the clutch on a Punto a couple of years ago and 'lost' a couple of gears. Turned out that I had not seated the rubber cover for the gear linkages as the enter the gearbox correctly. This meant that they did not have full travel and so could not select 1st or 2nd. A 30 second fix once I had worked it out and finished swearing!

Might be as simple as that.

Mark
 
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