Classic stiff clutch and low engagement problem

[sd240]

A little history first, I put a SBR 3500 Clutch in my car, had a fairly low engagement point and pretty stiff pedal pressure, but it was still drivable. The SBR disk puked out two of the springs in the clutch and got lodged between the PP and Disk causing me to drive about 30 miles rev-matching and rolling through stop signs until I got home. I then put a stock clutch in and a washer under the clutch fork pivot ball causing light pedal pressure and perfect engagement position. I then drove like an idiot on the stock clutch and burned it up. Finally I decided to try the stock disk with the SBR pressure plate (talked to somebody from SBR and was told that he didn't see why that wouldn't work, but he wasn't too supportive of it). When I got that combination in the car I jumped in all excited, mashed on the clutch, and then cried (well almost).

The Clutch pedal is very stiff and car will only go into gear while it's running if you literally stand on the clutch pedal and almost force it into gear, except reverse, it grinds and makes me cringe. There is absolutely no way you can drive this car daily or especially race it and the drags are starting to come to a close around here. Before you all go shooting out ideas here is all the information I can think to give you that might deal with the problem... 93 TSi AWD with 6-bolt engine stock flywheel and tranny out of a 90 TEL. I've replaced the master cylinder, slave cylinder, pedal assembly (salvage yard unit but had absolutely no pedal play), replaced all clutch lines, including rubber section, with all hard metal brake lines, new pivot ball and clutch fork, and the master cylinder adjuster rod thinggy is just about all the way out. Now does anybody have any ideas...Please?

 

[Pirrofab]

just thought i should let u know you are definatley not alone, im experiancing the same problem on my fwd. stock set up for clutch and the pedals catches very low but pedal feel is stock. i was assuming it was due to slave cylinder push rod length and a worn pivot ball. i've also read about the master cylinder push rod sometimes being bent. try an adjustable push rod for the slave cylinder. also might want to consider step height for the flywheel and clutch assembly ... its worth the shot to look into.. just would stink to rip it all back apart

 

[sd240]

Oh! Thank you, I forgot to mention, I also have the extended slave cylinder rod, I think it came from SBR.

 

[sd240]

Seriously, any input would be greatly appreciated.

 

[oldman]

Seriously, any input would be greatly appreciated.

Do not bump your thread again, ever.

just thought i should let u know you are definatley not alone, im experiancing the same problem on my fwd. stock set up for clutch and the pedals catches very low but pedal feel is stock. i was assuming it was due to slave cylinder push rod length and a worn pivot ball. i've also read about the master cylinder push rod sometimes being bent. try an adjustable push rod for the slave cylinder. also might want to consider step height for the flywheel and clutch assembly ... its worth the shot to look into.. just would stink to rip it all back apart

Please use proper grammar, spelling (no "u"), punctuation and capitalization in tech sections.

sd240, Did you bleed the clutch? If so, describe the method and procedure.

 

[c4uldr0n]

Oh! Thank you, I forgot to mention, I also have the extended slave cylinder rod, I think it came from SBR.

This is a bandaid fix. I would find your "real" problem and ditch the extended slave rod.

 

[JrCRXHF]

I have a ACT 2600

I did most of the install but had my dad's friends shop finish up because i had to go back to College so i don't know what they machined the flywheel too. But i have been fighting a stiff clutch petal for 2 years now. I have replaced a broken clutch fork a new mater and slave cylinder and also have a stainless clutch line and new pivit ball. The Clutch is still much stiffer then other ACT 2600's i have driven in the past.

So if you have checked all the things like i have checked i would go back and look at the flywheel and make sure that the step is in spec.

 

[sd240]

Do not bump your thread again, ever.


Please use proper grammar, spelling (no "u"), punctuation and capitalization in tech sections.

sd240, Did you bleed the clutch? If so, describe the method and procedure.

I am sorry, truly. I'm getting desperate, but I assure you that it will not happen again. Thank you for all that have replied. I have blead the clutch with a vacume pump, with somebody siting in the car and pumping it, and by gravity bleeding it. The second time I blead it a very tiny amount of air came out, but the three million times after that no air has ever came out, so I don't think bleeding is the solution. Again thank you all.

 

[oldman]

I am sorry, truly. I'm getting desperate, but I assure you that it will not happen again. Thank you for all that have replied. I have blead the clutch with a vacume pump, with somebody siting in the car and pumping it, and by gravity bleeding it. The second time I blead it a very tiny amount of air came out, but the three million times after that no air has ever came out, so I don't think bleeding is the solution. Again thank you all.

At any of these attempts, did you attach a vacuum line to the bleeder valve and submerge the other end in fresh fluid? If not, you're sucking air back in through the bleeder valve after each bleed, repeat the buddy pumping/vacuum line method, you will be surprised at the results.

 

[sd240]

Yes sir, I sure did. I'll try bleeding it all again taking extra caution to make sure no air gets in, but I'm almost positive that this isn't the problem.

 

[GST187]

I'm having the exact same problem also and its getting worse everyday. I'm running the ACT2100 and every attempt to fix it has only made it worse. Right after we installed the clutch and pressure plate(a good friend whose one of the top mechanics for a chain of local repair shops and myself assisting) I noticed the clutch pedal engaged literally 1/4" from the floor but, it was at least drivable. Soon after maybe weeks later the slave cylinder died so I replaced it and the master at the same time. We also bled the system each time with no change in the engagement. Low engagement aside the main problem has been shifting into first and reverse. We bled the system again a couple of weeks ago and adjusted the rod under the pedal as far out as it will go making things even worse. Now the clutch is not fully disengaging when the clutch pedal is pushed all the way to the floor. One other thing which no one has mentioned yet is (at least for me that is) these problems only occur after the car completely warms up. With the exception of the low engagement. Any help will be a blessing. Thanks in advance!

 

[pickens]

You need to bleed the line more. Sometimes it can take a long time to bleed an air bubble all the way through. If you bleed through half a bottle of new brake fluid you should be fine.