1G clutch pedal height/freeplay questions

[Tsi_User]

For the last few months I've been having problems shifting gears in general (all of them pretty equally) and at first i thought it could be bad syncros but i'm now thinking it might have to do with the clutch not completely engaging/disengaging properly.

I took a look in my manual and according to specs the clutch pedal height should be about 7 inches, mine is at 6.

Also, the switch that the clutch pedal engages when you completely let off the clutch doesn't completely get pushed in like the gas pedal switch does. It kinda seems like the clutch doesn't have enough stregnth on its own to fully push in the switch. Once I let off the clutch it comes back up normally but I can then take my hand and kind of pull up the clutch another half an inch to fully engage the switch.

Also, I know that our clutch system is hydraulic and i realized that today the cap on my clutch fluid doesn't screw on properly, like the tabs were snapped off. ALthough the cap does sit on there firmly it comes nowhere close to making a good seal. Is the resevoir itself pressurized and could this be a problem?

If anyone cal help me out on this it would be great. Sorry if my questoins are confusing, if need be i can take some pictures and post them up tomorrow morning.

Thanks!

 

[Ryan95tsiAWD]

Have you made any adjustments to the clutch before this started happening and is it leaking any fluid? Has it gradually gotten worse or all of a sudden? When was the last time you changed the pivot ball/shift fork or shimmed it?

 

[Tsi_User]

Have you made any adjustments to the clutch before this started happening and is it leaking any fluid? Has it gradually gotten worse or all of a sudden? When was the last time you changed the pivot ball/shift fork or shimmed it?

nope, didn't make any adjustments to it before it started happening.

It has slowly worsened over time and now it's a total paintin the ass to shift.

It doesn't seem to be leaking any fluid, the clutch fluid resevoir is at the exact same level it was at a week ago.

One other thing i forgot to mention is that when I push the clutch pedal all the way down it kinda makes two clicking sounds that I can actuall feel in the pedal. The sound however seems to be coming from inside the car, not from the engine side of the firewall. It also seems pretty hard or harder than it should to push the clutch all the way down.

 

[Generation1JeY]

I can then take my hand and kind of pull up the clutch another half an inch to fully engage the switch.

The problem is most likely your clutch pedal assembly. Read this write-up from TRE on clutch adjustment. Focus your attention on item #3.

Click Here

 

[Tsi_User]

The problem is most likely your clutch pedal assembly. Read this write-up from TRE on clutch adjustment. Focus your attention on item #3.

Click Here

thanks alot for the link dude, I'll take a stab at it tomorrow and report back

 

[Tsi_User]

it says on that write up that if i can pull the pedal up at all by hand I will have to remove the clutch linkage and remove it. I looked in my Haynes and couldn't find info on the clutch linkage. Anyone have a pic?

 

[laserturbo91]

have you figured it out yet? if not just post back and i'll tell you how to get it out

 

[oldman]

http://www.dsmtuners.com/forums/showthread.php?t=96981