Fulvia sans-clutch

We recently encountered a Lancia Fulvia that left the owner stranded after refusing to shift into any gear, whatsoever. The culprit was a seized pilot bearing. Which, as it turns out makes separating the gearbox from the engine – no easy feat. Removal involved sliding the gearbox back approximately 1/2″ to gain access to the bolts securing the pressure plate to the flywheel. From there, with a little brute force, we were able to pull the pilot bearing through the sheetmetal lock ring/retainer on the flywheel. 

Ideally, you should never have to remove a clutch disc, pilot bearing, and pressure plate as one assembly. The pilot bearing, in this instance, welded its self onto the main transmission shaft.

The inner section of the lock ring keeps the pilot bearing in the flywheel, and the flared edge on the center hole should not be there.

The original flywheel was cleaned up and resurfaced before being reinstalled with a new clutch assembly, pilot and throwout bearings, and a lock plate. We’re glad to the report the car shifted lovely after this service.