Technical Clutch pedal randomly goes hard.

[cmosfxx]

Clutch pedal on my 1.4 16v normally is very light and easy to push in upon cold start and remains like that for some time while driving when suddenly it becomes stiff and it's hard to push in the pedal.

If I keep pressing the pedal it's gonna be harder and harder.
Then after a while driving at a constant speed pedal becomes soft again etc.

Gear selection is good/the same, no matter the stiffness of the clutch.

What am I looking at? Pressure plate / master-slave cyl / fluid / pivot shaft ?

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[Avaxbox]

I know sometimes there is a problem with the fork they are less than £20

 

[cmosfxx]

I know sometimes there is a problem with the fork they are less than £20

Noticed a funny noise also.



This only happening when car is cold. After a 30min ride noise stops - pedal goes hard. :bang::bang::bang::bang:

 

[Jacob]

Sounds like a fluid issue to me.

I know little about the clutch system but it sounds like 'pumping' the pedal it is going from soft to hard. This also happens when hydraulic brakes need bleeding.

 

[cmosfxx]

Sounds like a fluid issue to me.

I know little about the clutch system but it sounds like 'pumping' the pedal it is going from soft to hard. This also happens when hydraulic brakes need bleeding.

I thought that the opposite happens when you have air in the system. Like you have a very light pedal and problems engaging gears etc.

ok a quick update:

Slave cylinder removed (but not disconnected from the line)
Clutch fork circlip removed
Fork removed
Fork Bush removed - BUSH IS PLASTIC LOL and actually has a lot of free-play.

I lubricated every part with white lithium grease and put everything back together.

Result:

Clutch is very very easy to press all the way now - gears engaging very smooth like before.

I don't know if the grease helped or it's something related to slave cylinder but the problem it's gone for now at least temporarily.

If it comes back I'll bleed slave cylinder and maybe replace the plastic bush too.

 

[Avaxbox]

I thought that the opposite happens when you have air in the system. Like you have a very light pedal and problems engaging gears etc.

ok a quick update:

Slave cylinder removed (but not disconnected from the line)
Clutch fork circlip removed
Fork removed
Fork Bush removed - BUSH IS PLASTIC LOL and actually has a lot of free-play.

I lubricated every part with white lithium grease and put everything back together.

Result:

Clutch is very very easy to press all the way now - gears engaging very smooth like before.

I don't know if the grease helped or it's something related to slave cylinder but the problem it's gone for now at least temporarily.

If it comes back I'll bleed slave cylinder and maybe replace the plastic bush too.

Did you get bush from dealers? I am going to try this with mine.

 

[cmosfxx]

Although the bush has a LOT of free-play that I don't think is normal, I used the same.

Bush part number:
top: 46543813
bottom (inside): 46543812

Let's see how it goes first. For the moment I'm very happy

 

[Avaxbox]

Although the bush has a LOT of free-play that I don't think is normal, I used the same.

Bush part number:
top: 46543813
bottom (inside): 46543812

Let's see how it goes first. For the moment I'm very happy

Some you just removed the top part which the slave pushes against as the release bearing is attached to the fork and would come off if you removed the full fork?

 

[cmosfxx]

wait, you can't remove the full arm fork to access the bottom bush without taking the whole gearbox out.
But you can remove only the top bush by removing only the part that slave pushes against, correct

 

[Avaxbox]

wait, you can't remove the full arm fork to access the bottom bush without taking the whole gearbox out.
But you can remove only the top bush by removing only the part that slave pushes against, correct

Good job sir I am excited to see if it makes mine feel a bit lighter.


Sent from my iPad using FIAT Forum

 

[cmosfxx]

Good job sir I am excited to see if it makes mine feel a bit lighter.


Sent from my iPad using FIAT Forum

I'm telling you mate, I don't know if the lubrication made the difference or something in the slave cyl is not right and when I removed it maybe gone back to place (maybe the tip, maybe air, don't know) but pedal is sooooo easy to press now. Let's see after a long ride in town tomorrow

Oh, it's impossible to put a clamp to the flex hose we talked yesterday. The hose it's very hard material.

I just let it sloooowly expand.

 

[Avaxbox]

Ok cool might try a cable tie then round the cylinder. Just don't fancy it flying out and sometimes they are hard to bleed.

 

[cmosfxx]

Problem came back after a long ride in heavy traffic. Gone when I got out and gain some speed.

Going to bleed the slave tomorrow and use new fluid. (Still the same from 2006) although I don't believe it's gonna fix anything.

 

[Avaxbox]

Worth a try sometimes I have seen fiats come in for service and the fluid is black,like treacle or yellow mush with water in

 

[cmosfxx]

Bleeding done.
Difference zero lol.

Now I have 2 options.

1) Master/slave cylinder check/replace (no leaks etc though)

2) Complete clutch replace. ( no slipping, light upon cold-start, gear shifting fine )

:bang:

 

[cmosfxx]

Today clutch pedal was rock hard even from cold start...

so...I decided to take another look down the forks' shaft.




I don't even know if all this play is normal or not

Then I dripped some oil down the shaft to lubricate the other bush like an Alfa Romeo guy told me to do.



Result:

Very light pedal again...

So this has nothing to do with the clutch/pressure plate itself.

Something I noticed and I don't remember if it's normal :

Pedal with engine off is a lil harder to press than with the engine on.

@Avaxbox

I'll appreciate if you test yours mate.

 

[Avaxbox]

Today clutch pedal was rock hard even from cold start...

so...I decided to take another look down the forks' shaft.


https://www.youtube.com/watch?v=fSkXSBT_Z48

I don't even know if all this play is normal or not

Then I dripped some oil down the shaft to lubricate the other bush like an Alfa Romeo guy told me to do.

https://www.youtube.com/watch?v=q6ujqjtkdLE

Result:

Very light pedal again...

So this has nothing to do with the clutch/pressure plate itself.

Something I noticed and I don't remember if it's normal :

Pedal with engine off is a lil harder to press than with the engine on.

@Avaxbox

I'll appreciate if you test yours mate.

Is the top bush missing on the video? I will try and look at mine when I get a minute clutch pedal is about 10 mm higher than the brake

 

[cmosfxx]

Nice thanks
So 1cm is normal.

Yup. I removed the bush so I can lubricate the other one.

 

[cmosfxx]

Stiffness came back again suddenly yesterday.

I removed slave cylinder again when I realized my hands were full of fluid.

Pushed the protecting boot all the way back and a lot of fluid dripped all over the floor.

So...slave gone for sure.

 

[cmosfxx]

So... here's the fix :

Clutch and slave replace.

Disc was ~~fine but pressure plate and bearing gone

I'm driving a new car btw