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159 Clutch Clunk

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12K views 39 replies 10 participants last post by  johns159 
#1 ·
Hi all,

My 159 has started making a clunking noise which you can hear and 'feel' when selecting first gear. I can replicate this on demand and the car does it every time.

If I brake and come to a stand still then put the car straight into first it doesn't happen. However, if I slow to a stop, put the car in neutral and release the clutch then depress the clutch and select first I get a clunk noise and you can feel it through the car.

It is definitely something to do with letting the gear stick move to the neutral position because as I said before, I get no clunk if I slow down in second and then select first straight from second when stationery. If I knock the car out of gear and release the clutch, when I press the clutch to select first it then happens.

Does that make sense?:cheese:

I've had a look elsewhere and seen others have reported clunking noises but this seems to be when changing gear in motion, however may possibly be related but I haven't noticed this noise whilst moving.

Thanks in advance for any suggestions.:thumbs:
 
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#2 ·
Mine's the same and it's only gotten worse with time:( It kinda sounds like driveline shunt. I think my gearbox is shagged as the always poor 2nd to 3rd change is really crunchy on anything other than a real slow change. Add that to clonky rear suspension & a nasty dash buzz and I think it's time to take it to my dealer:(
 
#5 ·
Thanks for the response guys.



Yeah, I read a few similar issues, wasn't sure if this was what I was suffering from as I only notice it whilst stationery.


Try puting the car into reverse. Does it snick in easily or does it crunch? if it crunches it's likely the clutch, if not then it's first gear. Sometimes 'showing ' the lever towards second then going into first in one movement will make selection easier.
That's exactly what happens.:thumbs::mad:

Can anything be done or is this another 'characteristic'?
 
#4 ·
you've got one of two problems here.Either a. the first gear syncro is worn or, b. the clutch is dragging. Try puting the car into reverse. Does it snick in easily or does it crunch? if it crunches it's likely the clutch, if not then it's first gear. Sometimes 'showing ' the lever towards second then going into first in one movement will make selection easier. These comments are general observations on clutch/gearbox behaviour. Although I've had lots af Alfas I have'nt done more than 15 or so Alfa clutches over the years, and no 159s.My brera gearbox (same part I think) does'nt missbehave in any way so I can't say yeah they're all like that. Hope this helps
 
#8 ·
The car doesn't clunk in reverse or any other gear as far as I am aware and has covered almost 12k miles.

I should perhaps point out that the gear box feels very stiff when used for the first time each day but does loosen off after a short time, I'd assumed this was normal as my boss's A4 diesel does the same. Could this be related?
 
#9 ·
Hi I get a small clunk changing from 2nd to 3rd at lower revs.

I will be calling my local dealer about it, it does not seem serious but it does sound like something is not quiet right.
Yep, mines the same and only really audible at slow speed.

All gears are smooth with the exception of a quick, high rev up-shift from 2nd to 3rd.

A slow 2nd to 3rd up-shift is smooth though:confused:

Worried as mine is getting really quite crunchy:(
 
#12 ·
Ok so the clunk happened and to start off with they have lubricated the gearbox area which as made it slightly better.

If it gets worse they will look further but in the mean time they are going to see if it happens on more 159's they get in.

On another note the squeaky clutch (which I thought was just a cable problem) is going in for a replacement master cylinder.

Also they are going to locate a dashboard squeak that only happens when it is dry weather!
 
#15 ·
presumably the diesels are fitted with dual-mass flywheels which are problematic accross a whole range of vehicles. On common vehicles such as ford transits it's possible to get a solid flywheel replacement kit. I don;t know why they just don't fit these as standard as they are made by Valeo who used to make clutches for alfas (nowdays I think it's LUK who love DM flywheels).
 
#17 ·
Exactly the same as on mine but on original clutch.

The drive-line noise when changing gear at lower speeds is getting really annoying now though so I need to get it sorted.

Can someone please confirm if the 2.2 petrol cars have a DM flywheel?
 
#18 ·
The clunk on mine has also become apparent on gears other than only 1st as I originally reported. Although frustrating I still love the car and honestley believe that the majority of Alfa owners are car fans in general and are therefore likely to be a bit more vigilant/picky when noises and problems occur.

I can live with it but my concern is that being a company car, my boss won't and it is niggles like these that will prevent me from being 'allowed' an Alfa instead of a 'reliable' German alternative.:mad:
 
#19 ·
I can live with it but my concern is that being a company car, my boss won't and it is niggles like these that will prevent me from being 'allowed' an Alfa instead of a 'reliable' German alternative.:mad:
That's exactly my concern, we have a number of German machines that only ever go into the dealership for servicing whereas I try now to take the Alfa in without anyone knowing. The other issue is when you have clients and colleagues in the car you tend to turn the radio off and it's rather embarrassing when they comment on the suspension rattles and gear clunks.
 
#20 ·
I too get the same between 2nd and 3rd. Also have a clunking from rear suspension. Will ask my local alfa dealer (Donalds of Peterborough) if this is something they know of. Car out of warranty with Alfa, but have 2 months remaining from dealer purchased car from (not an alfa dealer),
 
#21 ·
Mine only does it from 1st to 2nd. I feel a little left out:cry:! My Ti works the other way round too - fast changes are fine, slow changes can 'crunch':confused:. A double de-clutch between changes always cures the problem - seems daft on a modern car though. Also tends to be worse when cold, the change improves when the gearbox oil has warmed through.

Steve.
 
#22 ·
Mine is now clunking if i say lift off the gas in 2nd or 3rd below 30mph and the re-apply the gas.

The only time I have ever heard a sound like it ony previous car I owned it was a lose engine mounting but that then caused it to happen at any speed.

Once over 40mph it virtually disappears.:confused:
 
#23 ·
I wondered if it was an engine mount, particularly as the engine came out for some work. When in traffic I find myself lifting the clutch pedal to hear and feel the clunk to try and identify what it is. I keep assuming it's the clutch because that doesn't work properly anyway, particularly on cold mornings when you have to lift the pedal up.
 
#29 ·
Hi, went in this morning. They did not want to book it in took them out for a test drive and they said they could not ear anything out of place.
Could be just that I am hearing the dual mass fly wheel slapping back.

I must admit after a 4 modern diesels before I have never heard a clunk but after seeing how one work it could be possible.

I suppose it could explain the cluck on changing up also.

Anyway a year of warranty remaining if it gets worse I will take it to another Alfa garage for a second opinion.

Can anyone recomend a good one for shropshire or west mids
 
#30 ·
I took mine in to Budgens in Shrewsbury for similar clutch slap on gearchanges between 2nd and 3rd, they could not find fault either, not sure if this is where you have been this morning but there is another Alfa dealer in Willenhall. You could try taking it to an independant such as WAD in wolverhampton, they might have a look and tell you what the problem is for a small fee..... they diagnosed my 156 within minutes when i first used them something the dealers could not fix in 3 days!
 
#31 · (Edited)
Did Shrewsbury it was a case of carry on until it gets worse.

Spoken to a techy at guest willenhall as I wanted a 2nd opinion.

He said sounds the same as one they done last week. Dual mass fly wheel.
It was not the clunk in changing gear that was the problem but the delay and clunk when coming off power and reapplying power when the transmition had warmed up.

They sound really helpfull book in for 3 days for full diag on the problem.

I was relived to hear it was not right more than anything else. I was begining to feel fussy even though I knew it did not seem right.
 
#32 ·
Took my car in for its first service today. I mentioned the clutch clunk I am experiencing (along with uneven tyre wear and windscreen creak). Surprise, surprise, this is normal for the 159 they tell me. Do they really believe I'm that stupid? After all, they gave me a 159 loaner to go and get some breakfast as the nearby pub's chef had not turned up. The first thing I did was try to replicate the noise in that car, was it there? No! Therefore not normal in my book.

I am going in next week when the service manager is in and discuss my options with him before taking it to an independent for a second opinion if I have no satisfaction.

It leaves me with mixed feelings about the dealer as they were kind enough to give me a loaner, albeit by the general manager who knows me on first name terms after the early issues I had with my 159, and have gone the extra mile on many occasions to assist me when ARUK have not. However, the service department also told me that uneven tyre wear is normal and the pull in my steering is due to the 19" ti wheels tram lining. Why does it always pull to the left then?:mad: Oh, and the windscreen still creaks, perhaps worse than before if that's possible. I digress!!

I am driving to Germany next month, hopefully via France, Italy and then Belgium on the way home. I know I have European cover but I really don't want to have to use it whilst away.

I will keep you posted.
 
#33 ·
Be good to know how people get on with this, taking mine to WAD (Independant specialist) next week for service, Budgen quoted £440, if i wanted oil change as well, but said they could not say for sure what the cost would be:rolleyes:????..... I have asked WAD to look at all my problems inc clutch clunk, for which im prepared to pay the labour if it means i get resolution, just concerned the dealer will get a bit stroppy when they realise they arent getting the servicing! Still got 8 months warranty left so need to get these resolved sooner rather then later.....

WAD quoted £195.... they would do it as it is laid out in the Service book, which some of the things Budgen mentioned it would include seemed a bit above and beyond.
 
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