Hi
First of all thanks for the help and information that I've gleaned since joining a couple of weeks ago and assisted me in obtaining a '98 Weekend ELX 20v.
Bought from a small dealer who gave a 3 month warranty so I'm keen to get everything right! There have been a few niggles and a couple of bigger issues but now something is brewing which, I suspect, is going to test the dealer's interpretation of warranty...

I'm not a mechanic but been driving long enough to 'feel' when things aren't right and I had a different garage look at clutch/gearbox, their diagnosis was that the pressure plate assembly was failing.

The symptons are erratic, sometimes the clutch/gear change feels perfect, then other times notchy (can feel the gear engaging). On one occasion, after stopping, I could not select any gear at all, clutch felt fine but could not move the gear lever into any slot from the neutral position. Called the AA and waited - then after about 3rd time of re-starting engine everything was working perfectly!

Took it back to dealer and his mechanic reckoned it was not the clutch but adjusted 'some linkage'. Now, very often, I can't select gears even when moving (this has happened at speed on the motorway!), sometimes have to use a great deal of force to move gear stick, and, for example, coming to a standstill in second and depressing the clutch feels like it's still engaged and have to knock it out.

Sorry about the rambling post but I hope that giving as much info as possible might help someone give me some pointers before I challenge the dealer again.

Perhaps it isn't the clutch, what about selectors, linkages etc. or the gearbox itself?

I've had similar experiences on a 1966 Land Rover off all things which would lock you out of gear as the synchromesh on 3rd/4th was eating itself. Once the offending part of the synchro had fallen into the bottom of the gear box, it would drive as if nothing had happened.

The Land Rover synchros are pretty antique and I would hope that most modern ones are better designed so it shouldn't be this.

The selector forks/shafts are a more likely option. If you have wear in the mechanism that's allowing 2 forks to move at the same time the gear lever will just lock up and this is probably the linkage the mechanic adjusted. How much of a difference did it make when he adjusted it last time?

When you said " coming to a standstill in second and depressing the clutch feels like it's still engaged and have to knock it out " did you mean that even with the clutch depressed the engine was going to stall if you didn't knock it out of gear? If this is the case then that points towards a problem with the clutch!

<The symptons are erratic, sometimes the clutch/gear change feels perfect, then other times notchy (can feel the gear engaging). On one occasion, after stopping, I could not select any gear at all, clutch felt fine but could not move the gear lever into any slot from the neutral position. Called the AA and waited - then after about 3rd time of re-starting engine everything was working perfectly!>
Sounds like clutch slave cylinder. Check for hydraulic fluid leaking onto top of gearbox. Losing any hyd fluid from reservoir? What sounds odd is that you say "clutch felt fine", clutch usually feels different when slave cylinder failing-hi bite-lo bite- feeling easy (nothing happening) -then normal

When you say you "can't select any gear after stopping", try turning engine off, clutch down get any gear then? All OK? again sounds like slave cylinder

<Took it back to dealer and his mechanic reckoned it was not the clutch but adjusted 'some linkage'. Now, very often, I can't select gears even when moving (this has happened at speed on the motorway!), sometimes have to use a great deal of force to move gear stick, and, for example, coming to a standstill in second and depressing the clutch feels like it's still engaged and have to knock it out.>
Slave cylinder

Costs about £30-£40. Easy to fit. For the moment, when you can't get gears try pumping the clutch. Probably get the brake warning light coming on soon when hyd fluid loss gets significant

Hi

Thanks for the reply.
I was suspicious that whatever the mechanic did with the 'linkage' didn't make any difference with the clutch/gears, they also fixed an ABS problem (CV joint assembly) and a brake sticking/binding problem which, as you can imagine, made the car feel totally different. The clutch/gears have deteriorated much more in the days since I collected the car after the 'fix' - so whether they did anything or not, it's on it's way out!

Yes, the car does nearly stall when pulling up in second gear (on occasions) so it does point to the clutch, but I'm wondering if there's more than one problem...

My dealer is still having difficulty replying to my calls...

I'll have a look for fluid, but my 'local mechanic' did check this out (and bled the system) when I got him to give the car a total check after initially buying it...

Fluid levels are fine and no signs of any leaks....

Could be the same as what happened to mine, hope not though...

https://www.fiatforum.com/showthread.php?t=28087&highlight=inside

Thanks for that, it might just be the answer...and I do have this 'warranty', if I can get my dealer to call me back, 'though he's probably too busy putting more bunting out!

Unfortunately does sound like mine (clutch driven plate spring), also discussed in previous post.

Mine only lasted a few days after it started playing up before refusing to disengage at all...

Slave cylinders are known for leaking also, although doesn't fit your symptoms.

Best hope for you is that it does fail completely ASAP so then there can't be any question about the warranty!

Good Luck,

Mark.

Thanks, I'll post as soon as I get the solution.

OK, for those interested it's sorted out now.
Apparently it was the Master Cylinder (leaking/bypassing?) but this was not spotted and resulted in damage to the Clutch itself.
So new Master Cylinder and new Clutch, on 'warranty'!

Thanks to everyone for their experience and guidance - it certainly helped me when talking to my 'dealer'.