Somebody give me an idea

[94_TSi]

Alright heres the deal guys just got done putting a buddys car back together for him. Its a 94 tsi fwd 5spd car with a 6 bolt. After finishing the engine, it needed timed, head installed all that jive, the clutch is acting up. Will not disengage for anything!! Obviously it wont go into any gear while running and pulls itself if i put it in gear with it off then crank it.... The clutch is a Competition clutch stage 5, 4 puck sprung with about 700 miles on it that worked fine before. Now before i get all the replys read this list of what i have done.

New master and slave cylinders
SS line from master to slave
Blead system 12 or 13 times
checked and played with master cyl adjustment, currently have it all the way out(furthest pedal movement)
Threw in a 1/4'' longer slave rod when i got pissed
Pulled trans back out re aligned disk and pressure plate
double checked pressure plate bolt torque
Already has shimmed pivot ball
Put on a clutch fork from my car, I know its good

Heres the only thing I can think of when i inspected his stock flywheel it was very easy to see it had huge cracks in it. I replaced it with another stock one I had and just hit it with some sand paper. Seems to me that if the step height was off it would give me the opposite problems like clutch slipping? Any thoughts are much aprreciated.

 

[dsm03]

Synchros?

 

[NOSLO2PT0]

You didn't step the flywheel to the clutch specs. That thing will never disengage properly unless your flywheel is stepped to whatever the clutch mfg recommends.

 

[Aproductions]

yeah I would check the tranny itself.

if not, look at the clutch setup....try swapping it and see if it works then.

also look at the tob and fork....forks can bend.

so basically just trial and error.



1. tranny (gears/synchros)
2. pressure plate, disk, flywheel
3. tob and fork


you pretty much did everything else

You didn't step the flywheel to the clutch specs. That thing will never disengage properly unless your flywheel is stepped to whatever the clutch mfg recommends.

i forgot that, that is really important

 

[94_TSi]

Synchros?

The trans was fine before.

You didn't step the flywheel to the clutch specs. That thing will never disengage properly unless your flywheel is stepped to whatever the clutch mfg recommends.

Our flywheels are -.610, competition clutch's are made for -.610.

yeah I would check the tranny itself.

if not, look at the clutch setup....try swapping it and see if it works then.

also look at the tob and fork....forks can bend.

so basically just trial and error.



1. tranny (gears/synchros)
2. pressure plate, disk, flywheel
3. tob and fork


you pretty much did everything else





i forgot that, that is really important

Everything you mentioned was fine before and for step height i answered that.

Also i forgot to mention there are zero leaks.

Anybody else wanna throw somethin out there?

 

[94_TSi]

Ya its a little over a year later. The car was parked and not touched until recently. After everything that was done with no progress, the only thing left was the pedal assembly. Pulled it sent it off to shep and got it back. IT TOOK CARE OF ALL THE ISSUES IT WAS HAVING! Just wanted to let everyone know.

 

[RipperXX]

So the pedal assembly just had to much play in it? BTW, curious if all 1g's have the same assembly?

 

[Boostinsideways]

I wish I would have seen this sooner. I've had that pedal issue with every 1g I have ever driven.