FW: Help with hydraulic clutch diagnosis - 166/164

[Martin Jacques <martin.jacques@xxxxxxxxx>]

First of all, a big thank you to all who offered advice on my clutch
diagnosis. I am slowly learning the art of problem daignosis, but I am still
a way from it yet.

I have pressurised the system this afternoon, using a Gunson's Eezibleed. I
used just air (no brake fluid) and put 20psi in the wheel I was using. After
2 1/2 hours, the pressure in the tyre was down to 10psi. So, I surmise that
there is an air leak somewhere. No fluid leaks anywhere, which really does
make finding the problem harder. I have tried to find the air leak aswell,
but no joy - I guess 1-psi in 150 minutes is a pretty minor leak.

My hunch is the master cylinder, so I think I shall just replace it - well,
I am going to try and persuade my dealer to do it under warranty anyway.

Hopefully, that will do the trick.

Many thanks again,

Martin.


-----Original Message-----
>Folks,
>
>I am hoping that someone can help me with some diagnosis. My problem
relates
>to the hydraulic clutch on my 1999 166 3.0, but I believe that the 164
>system is almost identical. I also imagine that there are far more 164
>owners with experience of working on their cars than 166.
>
>3,000 miles ago, the clutch hydraulics went soft, there was three or four
>inches of free travel in the pedal, and I could not fully disengage the
>clutch. The car went to an Alfa dealer, who diagnosed and replaced the
>master cylinder. The car was perfect for about 1,000 miles, until the same
>free travel occured again. The car went back, the clutch was bled, and all
>was well once again.
>
>This problem re-occurs every 500 miles or so now, and nobody can find any
>fault. The car is perfect for 400 miles, then a gradual decline until I
>cannot disengage the clutch any more. Either the dealer or myself can bleed
>the clutch, and it is ok again for another 500 miles.
>
>The thing that is really stumping me, is that there is no noticeable drop
in
>the fluid level in the reservoir. This suggests to me that there is not
>really a leak, but more of an intake of air somewhere. I have had a pretty
>good look at the master cylinder in situ. Both the outlet to slave, and the
>inlet from reservoir "look" fine to me. The pipework from reservoir to
>master cyl routes through the bulkhead, and behind the centre console so
>that is hard to check.
>
>It has been suggested to me that as there is no real leak, it must be on
the
>'suction' side, ie inlet into m.cyl from reservoir. It looks fine to me,
but
>any suggestions on how to check this further - all I can think of is soapy
>water?
>
>If anyone can offer any tips, or suggestions, I would be very grateful.
This
>is proving a real puzzler for both myself, and my dealer.
>
>Many thanks,
>
>Martin (UK).
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