Mid-Production Clutch Diameter Increase
Tim Hodgkin, Technical Support Technician at ZF Services UK advises that early 1.0 litre models of these vehicles equipped with the five-speed manual gearbox suffered from premature clutch wear. Many owners complained of slipping clutch, noise from the clutch during stop/start motoring, or burning smells, and as a result, the vehicle manufacturer upgraded the clutch from 180mm diameter to 190mm.
Replacement clutch kits should contain the later 190mm diameter version with heavier clutch cover, and technicians should be aware that this will appear different if they are removing the original 180mm clutch. The condition of the flywheel should also be checked due to the increase in driven plate diameter; any scoring or wear ridges indicate the need for skimming or replacement. ZF Services UK can provide technical support if required.