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Technical Fiat Stilo 2005 1.8 16v clutch Pedal probs

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Technical Fiat Stilo 2005 1.8 16v clutch Pedal probs

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stiloguy

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Hi all,

I have a Fiat stilo 1.8 16v 2005 that has a weird problem, the clutch works fine but sticks at the bottom when fully pressed down, if you can convince yourself to leave 1" before the fully pressed down position it is fine but sticks most times when fully depressed (BTW it is not the carpet). I used to be a mechanic many years ago but have limited experience with clutches on Fiats so any advice would be appreciated before I end up taking the gearbox out. Got a nasty feeling this might be what needs to be done? But fingers crossed.

I have removed the pedal noise reduction cover and I notice that there are two components + switch that the clutch pedal operates can anyone tell me what these are called? And if there is a common problem with these? I could take a picture if needed

I did give one of the components a squirt of wd40 last night whilst examining the clutch pedal operation ,but it didn’t seem to do anything BUT the pedal worked fine for 50 -100 times this morning before it started sticking again which started again after a few miles trip when reverse was selected, air in system? Clutch slave cylinder? Coincidence?
From what I can gather from reading this forum and other posts online this model seems to have an internal clutch slave cylinder is this correct?

Any help knowledge on these motors would be greatly appreciated, struggling to get a book on this car although I am trying to download one as a type this message.

Sorry for the millions of questions J
 
This may seem like a bit of a daft reply but mine does that when the floor mat slips forward:D! The pedal catches on the edge of the carpet. Just make sure it isn't something as daft as that.(y)(y)
 
stiloguy said:
Hi all,

I have a Fiat stilo 1.8 16v 2005 that has a weird problem, the clutch works fine but sticks at the bottom when fully pressed down, if you can convince yourself to leave 1" before the fully pressed down position it is fine but sticks most times when fully depressed (BTW it is not the carpet). I used to be a mechanic many years ago but have limited experience with clutches on Fiats so any advice would be appreciated before I end up taking the gearbox out. Got a nasty feeling this might be what needs to be done? But fingers crossed.

I have removed the pedal noise reduction cover and I notice that there are two components + switch that the clutch pedal operates can anyone tell me what these are called? And if there is a common problem with these? I could take a picture if needed

I did give one of the components a squirt of wd40 last night whilst examining the clutch pedal operation ,but it didn’t seem to do anything BUT the pedal worked fine for 50 -100 times this morning before it started sticking again which started again after a few miles trip when reverse was selected, air in system? Clutch slave cylinder? Coincidence?
From what I can gather from reading this forum and other posts online this model seems to have an internal clutch slave cylinder is this correct?

Any help knowledge on these motors would be greatly appreciated, struggling to get a book on this car although I am trying to download one as a type this message.

Sorry for the millions of questions J
Click to expand...

You are right that the slave cylinder is inside the gearbox. Check for leaks around the bellhousing as the slave cylinder could be leaking. Does the clutch pedal feel soft when pressing it?
 
katanabandit1 said:
This may seem like a bit of a daft reply but mine does that when the floor mat slips forward:D! The pedal catches on the edge of the carpet. Just make sure it isn't something as daft as that.(y)(y)
Click to expand...

thanks katanabandit1 if only it was that simple, i dont have a mat in the drivers footwell so i know its nothing daft like that and ive already checked the carpet. worth a try though cheers.
 
MarkThompson4 said:
You are right that the slave cylinder is inside the gearbox. Check for leaks around the bellhousing as the slave cylinder could be leaking. Does the clutch pedal feel soft when pressing it?
Click to expand...

Hi Mark, there does not appear to be any leaks its very clean (50k), the pedal is pretty soft you can engage gears when the pedal is pressed perhaps 2-3" bit further is required for 1st and reverse, very smooth no crunching.
 
Sorry mate! Obviously something else then. Mine a bugger with the carpet slipping forward and its the exact symptoms you described. Good luck with sorting it though fella. Would be interested in what is actually causing it on yours (y)
 
katanabandit1 said:
Sorry mate! Obviously something else then. Mine a bugger with the carpet slipping forward and its the exact symptoms you described. Good luck with sorting it though fella. Would be interested in what is actually causing it on yours (y)
Click to expand...

i'll keep you posted once i get to the bottom of it, have you got a workshop manual for this car? that you can share?, i tried to download one from about 5-6 different sites with no success. the one on this forum seems to have expired.
 
stiloguy said:
Hi Mark, there does not appear to be any leaks its very clean (50k), the pedal is pretty soft you can engage gears when the pedal is pressed perhaps 2-3" bit further is required for 1st and reverse, very smooth no crunching.
Click to expand...

Is there much resistance from the pedal when you're pressing it down?

Click here: https://www.fiatforum.com/downloads.php?do=cat&id=5

Download the 6 elearn files into a folder (make one called elearn). Once all 6 are downloaded extract them using win rar (search google and download if you've not got it). Then use img burn to write the extracted file to a blank cd. You should then get a cd icon with elearn under it, click on that and it should run elearn. It gives you a lot of information about procedures and diagnostics, seeing as there's no haynes manual for the Stilo it's the best thing for you (y)

The other two things I can think of are either the clutch system needing bled or the master cylinder needing replaced. May be wrong :rolleyes:
 
Faulty slave cylinder usually leaks, and when you lift the pedal up, it takes more fluid from the reserve. I only got around 8 gearchanges (and at intersection after 10km of freeway my pedal was alredy to floor due to slave leaking) from Marea before it ran out of stuff and I had no clutch anymore.
The springs in the clutch assembly lift the clutch off the bottom, and when released, the mastercylinder/pedal has spring that keeps the pedal in released position (eases on the thust bearing so its not riding all the time.
On marea the spring also keeps the pedal down when it has crossed cerentain point, to lighten the clutch a littlebit.
Only thing I could see causing the jam is something on the pedal end as I do not know much about the internal slave cylinder and its operation.

When pressed down, does the pedal become light at somepoint... or does it come up when released, but suddenly catch something so no force is required to keep the pedal pressed?
 
MarkThompson4 said:
Is there much resistance from the pedal when you're pressing it down?

Download the 6 elearn files into a folder (make one called elearn). Once all 6 are downloaded extract them using win rar (search google and download if you've not got it). Then use img burn to write the extracted file to a blank cd. You should then get a cd icon with elearn under it, click on that and it should run elearn. It gives you a lot of information about procedures and diagnostics, seeing as there's no haynes manual for the Stilo it's the best thing for you (y)

The other two things I can think of are either the clutch system needing bled or the master cylinder needing replaced. May be wrong :rolleyes:
Click to expand...

Cheers Mark your a superstar, im downloadin them as i type.

with regards to resistance i would say it feels like a good clutch the pressure is constant and light.
 
Neverth cant see any leaks, doesnt seem to be losing any fluid still at max level. the pedal pressure does not really change imo, feels perfect. when its pressed down to the max it sticks and stays down untill you get foot behind it or sometimes press it again it comes back up wonder if its a dodgy spring?

i have tried bleeding the system this afternoon but it didnt make a difference.
 
stiloguy said:
Cheers Mark your a superstar, im downloadin them as i type.

with regards to resistance i would say it feels like a good clutch the pressure is constant and light.
Click to expand...

This is an exploded view of the clutch pedal mechanism:

clutch.png

Have a check over of the components make sure they are secure. I've not heard of springs wearing out at all on the forum but give it a look anyway.

If that's all fine and you say there are no leaks then I would say removing/replacing the clutch master cylinder to see if that helps, if not then it's probably a gearbox-out job to get at the slave cylinder.

Here's the clutch master cylinder (number 1):

master cylinder.png

EDIT: Sidenote - the rod coming out the master cylinder in the bottom picture connects to part number 4 in the top picture ;)
 
Last edited:
MarkThompson4 said:
This is an exploded view of the clutch pedal mechanism:

View attachment 102963

Have a check over of the components make sure they are secure. I've not heard of springs wearing out at all on the forum but give it a look anyway.

If that's all fine and you say there are no leaks then I would say removing/replacing the clutch master cylinder to see if that helps, if not then it's probably a gearbox-out job to get at the slave cylinder.

Here's the clutch master cylinder (number 1):

View attachment 102964

EDIT: Sidenote - the rod coming out the master cylinder in the bottom picture connects to part number 4 in the top picture ;)
Click to expand...

Cheers, it looks like it was just the spring/unit. im so so lucky :)

thanks for the links mark, the download worked a treat.
 
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