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Old 26th October 2009, 20:08   #1
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Default Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

(Palio 1.2 2002 25k Km)

Driving to work, it was becoming hard to shift gears. Brake light kept coming on and off. Coming back in the evening, started the car, reverse gear gave a screeching noise. Brake light was on (I know there is a slight leak somewhere).

Jammed it into 1st and then second and somehow managed to nurse it home over 10km in heavy traffic using the same gear and brakes. (car used to move slightly forward even with clutch fully depressed).

Parked it at the mechanics in the evening.

Right now, once you switch on the engine, you cant put it into gear. When the engine is off, the gear shifter moves freely.

Looking through the palio users forum, seems like this is a problem with the clutch master cylinder.
Can someone confirm that.

2 other questions.

Would my clutch plate be fried by now?

Do i have to worry about the brake cylinders?

Thanks for your inputs
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Old 26th October 2009, 20:29   #2
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You have the causes pretty well narrowed down, it could be the plate or the clutch master cylinder.

As for the brake light, check the oil reservoir and the discs (am not sure if the palio has a brake wear indicator)
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Old 26th October 2009, 21:16   #3
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Quote:
Originally Posted by genesis View Post
(Palio 1.2 2002 25k Km)

Driving to work, it was becoming hard to shift gears. Brake light kept coming on and off. Coming back in the evening, started the car, reverse gear gave a screeching noise. Brake light was on (I know there is a slight leak somewhere).

Looking through the palio users forum, seems like this is a problem with the clutch master cylinder.
My Dad's 2002 1.6 Palio had the exact same problem including the brake light indicator coming on, gear whine when backing up. The stupid TASS couldnt even figure out where the leak was!

It was the clutch master/slave assembly. The parts and labour came to about Rs 3000. Fortunately the clutch was ok.

This is a common problem with older Palios especially those that have gone with no or irregular brake fluid changes.

I suggest you get the fluid drained and replaced whilst they fix the clutch master/slave units (please replace both).

Rgds,
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Old 26th October 2009, 21:31   #4
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The reservoir is the same for both clutch and brake cylinders. That's the reason why you see the break warning light glowing intermittently. Did you check the brake fluid levels by opening the bonnet?


I once had a similar problem (too much jerking while releasing clutch) and the problem was found to be a leaking slave cylinder. The brake fluid had to be topped up every week until I got the slave cylinder replaced.

Last edited by clevermax : 26th October 2009 at 21:32.
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Old 26th October 2009, 22:11   #5
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It is most likely the clutch master cylinder. conjunction with brake fluid.
Brake fault light comes on if the fluid level is low. Reservoir is same for clutch and brakes.
On a second thought, clutch may act up even if there is something wrong with brakes circuit. (dangerous).

Before jumping into anything, fill up the fluid and see if you can make the clutch work. also check for leakages.

Gears dont just jam like that.
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Old 27th October 2009, 21:13   #6
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Update: Problem resolved.

It was the slave cylinder leaking. Replaced it. The master seems okay for now.

The rear brake cylinders were also leaking slightly. I knew that before and had postponed fixing them. Got them replaced this time.

Process included bleeding both clutch cylinder and brakes.

Total damages around 2100. Of which 550 rs is labor.
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Old 30th January 2011, 21:00   #7
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

Hi

My friend drives a 3 year old Fiat Palio 1.6 Sport and had a similar problem yesterday. The car was making a screeching noise when changing gears (clutch depressed) and by the end of a 100km drive the gear just jammed into 2nd and he struggled to get it home. When shown to a local mechanic he popped the hood and released the gears and said all plates need to be overhauled and gave a 6k quote (approx). My first impression on clutch wear is that the car starts dragging (which is usually the first symptom of plate wear), which has never happened on this car. Questions

1. Is the diagnosis accurate?
2. Does it cost that much to change all plates?
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Old 31st January 2011, 20:19   #8
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

Quote:
Originally Posted by genesis View Post
(Palio 1.2 2002 25k Km)

Driving to work, it was becoming hard to shift gears. Brake light kept coming on and off. Coming back in the evening, started the car, reverse gear gave a screeching noise. Brake light was on (I know there is a slight leak somewhere).

Jammed it into 1st and then second and somehow managed to nurse it home over 10km in heavy traffic using the same gear and brakes. (car used to move slightly forward even with clutch fully depressed).

Parked it at the mechanics in the evening.

Right now, once you switch on the engine, you cant put it into gear. When the engine is off, the gear shifter moves freely.

Looking through the palio users forum, seems like this is a problem with the clutch master cylinder.
Can someone confirm that.

2 other questions.

Would my clutch plate be fried by now?

Do i have to worry about the brake cylinders?

Thanks for your inputs

Ditto same problem with the gears on my GTX. Hopefully the clutch is not fried. Hey can you also suggest/ refer a good/ knowledgeable/ garage for Palio? I will take the car may be this week for repairs.
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Old 1st February 2011, 16:50   #9
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

Quote:
Originally Posted by Radnam View Post
Ditto same problem with the gears on my GTX. Hopefully the clutch is not fried. Hey can you also suggest/ refer a good/ knowledgeable/ garage for Palio? I will take the car may be this week for repairs.
I use a local guy in chembur. Has his own small garage.
Not fancy (it is a shed) but knows his stuff and can diagnose and fix Palio mechanical issues. The local palio service supervisor had once pointed me to him

He does not have ECU equipment or other fancy stuff. PM me if you need details.
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Old 3rd February 2011, 17:04   #10
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

Quote:
Originally Posted by genesis View Post
I use a local guy in chembur. Has his own small garage.
Not fancy (it is a shed) but knows his stuff and can diagnose and fix Palio mechanical issues. The local palio service supervisor had once pointed me to him

He does not have ECU equipment or other fancy stuff. PM me if you need details.
Hey Genesis,
Problem solved, trust me with this experience always get a second opinion if you don't know the garage/ mechanic personally. I actually assumed the issue may be due to faulty clutch master/ slave cylinder and showed car to one of the local garage in my area and he said we'll have to change both the clutch cylinders first and if required the clutch assembly. I knew this guy for a while but never got the car repaired from him. Trusting him I bought both the cylinders (Master 1500/- and Slave 920/-) but then just thought of speaking to another guy from our area. He checked and found no leakages from both the cylinders, he bled the slave cylinder and voila problem solved. He said the slave cylinder had caught up air and that had to be removed. He did it by just bleeding the slave cylinder. He shyed away when asked for labour charges, finally said 50/- de do saab!
Now I have Clutch Master/ Slave cylinder as a spare, ready to sell if anyone wants it. Check it out on the Classifieds.
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Old 1st May 2011, 13:12   #11
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

I am facing similar problems
When I stop in traffic I put the gear i Neutral. Now while starting the lever won't slot anywhere. The clutch feels lighter. Attempt to put in reverse results into a screeching noise. Brake fluid is compltely topped up. Bleeding is done as well. However there is no improvement.
This problem does not always happen. Happens occasionally. Mostly in hot engine. Is it the master cylinder?
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Old 1st May 2011, 14:09   #12
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

I brought a cousin's 2001 1.2 EL palio to my place to get it serviced and make it usable. Car has not been used for the best part of 5 years since he moved abroad. Its done just 2k-odd in that time; total mileage is 36k. I got the battery charged and fuel lines opened up to get it going. A routine check revealed that the brake fluid was running dry, so topped it up. Had great difficulty in engaging the gears initially with a loud screeching noise coming when slotting into reverse. Managed to get the car to my place somehow (drove 12 kms) and to my surprise, I found the gear shifts getting better with each passing km. Now the car has been stationary at my place for a few days again (haven't found the time to go to FASC), I noticed the same issue with gears and I can't even slot it in first even for a second. Same question as oxyzen above - what's wrong here?
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Old 1st May 2011, 15:03   #13
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

Quote:
Originally Posted by nkapoor777 View Post
I can't even slot it in first even for a second.
How frequently is it occurring?
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Old 2nd May 2011, 14:51   #14
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

Quote:
Originally Posted by oxyzen View Post
How frequently is it occurring?
Like I said, I first drove the car last week. It had been unused for the best part of last two months. The issue surfaced when I started the drive to my place. Got better en route and gear shifts were pretty ok. And now, the car was parked for 3-4 days and its shown up again. I couldn't find the time this weekend to get a mechanic to see the issue. Hope to do it in the coming week.
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Old 2nd May 2011, 15:40   #15
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Default Re: Fiat Palio 1.2 2002 Gears Jammed (Is it the clutch master cylinder?)

nk - it could be jammed gear cable - ask the mechanic to free it up with WD40. ideally there should be two cables (one moves side ways and the other for slotting in gears)

but do check if the brake / clutch oil level is ok.

Oxyzen - check the driver's side floor for signs of clutch oil leak (if hydrolic) for leak from Master cylinder. it could be the gear cable as well.

Last edited by planet_rocker : 2nd May 2011 at 15:41.
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