International Lancia Forums

Hi

Just got my S1 Fulvia Zagato running after 29 years of non use. Car moves but clutch pedal is very high. All I hear a grating/ rumbling.
Tried to adjust it by turning nut towards body (windscreen) but still the same. I suspect it probably needs a new clutch plate / pressure plate & release thrust bearing.

QUESTIONS ANSWERS

1) Should I replace the clutch cable as well?
2) What is the clutch removal procedure?
3) Engine out or, drop the gearbox?
4) How long to remove / fit clutch? (have to relay this info to my mechanic
who is not familiar with Fulvias!
5) Easy or, difficult?
6) Any tips?

Many thanks

If no strands on the cable are broken, leave the cable. Otherwise replace it.

I can either take out the engine or take out the gearbox. Not much difference on NEW cars.

There is a Lancia book listing times for different jobs. Today I can type the number of a car into a computer and it gives the exact time for the job. This was not different in the sixties. Open the book, look up the job, read the time which is listed for the job.

There will be a moment for every car where the book becomes invalid. This is often after ten years and is one of the reasons Lancia and its dealers no longer support the car.

I can take out the gearbox. I start taking off the down pipe of the exhaust. It bolts to the manifold with three bolts. Easy to take the nuts off. Except when one or more of the bolts break. I now have to take the manifold off to weld new bolts (all three of course) to the manifold to be able to attach the down pipe again. Just one example. Another example: as a result of old accidents or rust on subframe or body there may be stress on the cross members of the subframe. I have to take of cross members to drop the gearbox. I may never be able to put the cross members back in exactly the same position.

If I take out the engine, I may find the inside of the bellhousing on the gearbox full of tar caused by leakage from the oil seal on the input shaft. I want the seal fixed because I don't want to have a bad clutch again as a result of oil leakage. To replace that seal I have to take off the bell housing. To take off the bell housing I have to take out the shaft. To take off the shaft I have to take off the rear off the gearbox. If not experienced it means taking out the gearbox. I am experienced. I can take out the shaft and bellhousing under the car. After three months I will discover that the gearbox leaks a lot of oil over the top. The gearbox has to come out and opened.

I can take out either the engine or the gearbox. For me it is like being in a traffic jam on the motorway. I am always in the wrong lane. Or am I? By being in the wrong lane I may have escaped a heavy accident. I will never know.

The series 1 Fulvia does have the old type of pressure plate. I don't know the english name for the system. If I translate the Dutch "lepelkoppeling" into English it would be "spoon-clutch". It is a brilliant sensitive clutch. A true driver's clutch. It is VITAL VITAL VITAL that it is adjusted perfectly. Take the flywheel, pressure plate and disc to someone who has the experience and the tools to adjust. Yes. Read it again. Take FLYWHEEL AND PRESSURE PLATE AND DISC to a specialist for adjustment. The same guy will put the correct new lining on the disc. The number of specialists has decreased after 1970 when the diaphragm clutch was introduced. I have to drive 60 kms up and 60 kms down to bring it and again when picking it up. Total of 240 kms.

When you talk to your mechanic be extremely sensitive. Take your mother, wife or daughter if necessary. If he indicates ever so slightly that he is not happy with the job, don't push him into it. He and you will be better of if you take it to a specialist.

Hi Huib,

Excellent advice. Thank you.

Did not realize that it is important to remove the flywheel to balance.

Should I replace the the oil seal on the input shaft?[

Thanks

You don't need to balance the flywheel. To adjust the pressure plate the pressure plate has to be bolted to the flywheel with the disc sandwiched in between. Also the table inside the flywheel may have to be skimmed.

No need to replace seal if not leaking.

Thank you Huib for taking the time.