I thought my clutch was worn because it was slipping under load, but now that I have taken it out it doesn't look too bad. I would really appreciate your opinion on this (see attached photos).
What is the most likely reason for slipping in this case? Oil contamination? There seems to be quite a bit of oily substance inside the bell housing, but it doesn't seem to be coming from the input bearing direction. Could my leaky rocker cover be the source?

The friction plate would be fine without the massive oil contamination.

The pressure plate splines are wet with oil. The flywheel side looks the driest part.

Gearbox oil has a distinctive smell so you should be able to compare what is inside the engine and inside the gear box and see where it has come from.

I find it hard to tell from the smell, but I think it might be gearbox oil. Also, there is play in the input shaft, I can move it around. This, in combination with the noise in neutral that disappears when depressing the clutch all points to the input shaft bearing?

I found a good guide for replacing the input shaft bearing: https://www.fiatforum.com/punto-ii/158346-input-shaft-bearing-renewal.html
Materials required are input shaft bearing, oil seal, gearbox oil and anaerobic sealant?

judderbar said:

The friction plate would be fine without the massive oil contamination.

The pressure plate splines are wet with oil. The flywheel side looks the driest part.

Gearbox oil has a distinctive smell so you should be able to compare what is inside the engine and inside the gear box and see where it has come from.

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PuntoEnthusiast said:

I find it hard to tell from the smell, but I think it might be gearbox oil. Also, there is play in the input shaft, I can move it around. This, in combination with the noise in neutral that disappears when depressing the clutch all points to the input shaft bearing?

I found a good guide for replacing the input shaft bearing: https://www.fiatforum.com/punto-ii/158346-input-shaft-bearing-renewal.html
Materials required are input shaft bearing, oil seal, gearbox oil and anaerobic sealant?

Click to expand...

The bearing has failed for sure. There will be no play on the new bearing. Replace the oil seal. You can reuse the gearbox oil since it lasts more or less forever. If you use permatex anaerobic get the instant gasket anaerobic. the flange sealant anaerobic is not for aluminium.

I'm having some trouble detaching the selector housing from the gearbox. The bolts are out, but it is held together by a green sealant. Any tips on how to do this would be very welcome.

PuntoEnthusiast said:

I'm having some trouble detaching the selector housing from the gearbox. The bolts are out, but it is held together by a green sealant. Any tips on how to do this would be very welcome.

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If all 5 bolts are out just lever it off with a wrecking bar.

https://images.ffx.co.uk/tools/ROU64412.JPG?w=1280&h=960&scale=both

It came off relatively easily with some gentle tapping of the hammer and some leverage.
The current bearing is a Koyo 6204R, although I don't know whether it is original. The bearing is still intact but has quite a bit of play.
The oil seal looks intact, but I guess I will replace it anyway.

If bearing has play - itll have worked the seal and stretched the little spring inside it

If you are doing bearing
You must do the seal


Ziggy

beware buying clutches off the internet
i once did a punto mk2b clutch 3 times before i realised it was a chocolate plate ,it looked fine too just a little oily like yours
my oil came from crank and worked its way out onto flywheel,really strange thing there were no stains anywhere
fiat dealer reckoned there were no crank seals this side of turin so it was special order at £25 it was to turn up that friday but never did,the dealer didnt even phone,never been to them again,i got a seal off andrew pages £8 delivered by a very nice young lady

I got a new Luk clutch set. By coincidence it was also fitted with a Luk clutch before. Just waiting for the oil seal and gasket sealant, turns out next day delivery is already stretching to almost a week..

I would heed S and B's advice, I also had a crank oil seal go on my HGT diesel. Caused oil all over the bell housing but none visble on the flywheel, mainly because the fly wheel flings it from behind and at 5,000 RPM there isn't a lot to help the oil stay stuck to the flywheel, however the clutch plate is a different matter.

Take the flywheel off and have a good look behind it, otherwise you risk killing your brand new clutch with the same oil leak.

AndyRKett said:

Take the flywheel off and have a good look behind it, otherwise you risk killing your brand new clutch with the same oil leak.

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Haynes is talking about new flywheel bolts if it comes off. Is that really necessary?

AndyRKett said:

I would heed S and B's advice, I also had a crank oil seal go on my HGT diesel. Caused oil all over the bell housing but none visble on the flywheel, mainly because the fly wheel flings it from behind and at 5,000 RPM there isn't a lot to help the oil stay stuck to the flywheel, however the clutch plate is a different matter.

Take the flywheel off and have a good look behind it, otherwise you risk killing your brand new clutch with the same oil leak.

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It seems prudent to replace the crank oil seal now that it is relatively accessible. Do I have to get new flywheel bolts though?

PuntoEnthusiast said:

It seems prudent to replace the crank oil seal now that it is relatively accessible. Do I have to get new flywheel bolts though?

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https://forums.vwvortex.com/showthread.php?4706040-safe-to-reuse-flywheel-bolts

After reading that VW thread, unless you use your clutch very aggressively, I vote for using loctite or the anaerobic sealant on the existing bolts. The Permatex behaves like loctite - check it out with a nut and bolt.

judderbar said:

https://forums.vwvortex.com/showthread.php?4706040-safe-to-reuse-flywheel-bolts

After reading that VW thread, unless you use your clutch very aggressively, I vote for using loctite or the anaerobic sealant on the existing bolts. The Permatex behaves like loctite - check it out with a nut and bolt.

Click to expand...

Thanks for finding that. I would prefer to use new bolts since they are cheap, it's just that I haven't been able to find any yet. Or are they standard bolts? If not then I guess I will have to reuse them.

PuntoEnthusiast said:

Thanks for finding that. I would prefer to use new bolts since they are cheap, it's just that I haven't been able to find any yet. Or are they standard bolts? If not then I guess I will have to reuse them.

Click to expand...

https://www.fiatforum.com/punto-ii/460472-torque-clutch-flywheel-bolts-1-2-8v.html