pedal assembly?

[BlackStar]

i just got my 90 tsi awd up and running and now i got a clutch problem. the pedal has tons of slop, but if i hold the pedal half way pushed in (till it has pressure) the clutch will engage. Also sometimes when i push the pedal in the engine surges and makes a slight grinding noise. If i take my foot all the way of the pedal (while driving) i lose almost all pressure in the pedal. Any help is appreciated.. thanks

 

[BrokenTsi]

Sounds like its a combination of both the pedal assembly and maybe the clutch master cylinder.

 

[BlackStar]

ok well is a better idea to get a new clutch pedal assembly or to have the one that I have welded up?

 

[BrokenTsi]

Sometimes welding can melt the plastic bushing thats inside the pedal if its not done correctly. Shep sells brass bushings for the pedal assembly. He also sells new assemblies. Its on his website.

Back in the day, before anyone made the brass bushings, I fabricated my own using bushings that ALMOST fit, so I modified the assembly and the bushings to accept it. It made a WORLD of difference in my clutch pedal.

If the lever is worn, I would replace it and install the brass bushings.

 

[BlackStar]

Ok so the story gets deeper...... i figured i would try and bleed the clutch before i took the pedal assembly and all that out ### I figured Id try something easy first, but when we bled it the first time the pedal stuck to the floor and now the clutch is not engaging at all!! The piston on the slave cylinder will not push backout until you physically push it out... could this be my problem? Oh also I have just about all fluid coming out of the bleeder not much air..

 

[BrokenTsi]

It could be the problem.

 

[SBR Joe]

Sometimes welding can melt the plastic bushing thats inside the pedal if its not done correctly. Shep sells brass bushings for the pedal assembly. He also sells new assemblies. Its on his website.

Back in the day, before anyone made the brass bushings, I fabricated my own using bushings that ALMOST fit, so I modified the assembly and the bushings to accept it. It made a WORLD of difference in my clutch pedal.

If the lever is worn, I would replace it and install the brass bushings.

I agree.

I really hope that its a hydraulic system problem for your sake. I re built my pedal assy once in my 90 FWD and my god....hands down the worst thing ive ever had to do to a DSM in a decade. I rue the day i ever have to do that again. Sorry, im sure it doesnt make you feel too good about it, i just think you deserve a fair warning haha. My fingers are crossed for you!

 

[BrokenTsi]

I had to do it twice and I have an 8pt cage in mine! I would rather paint my car with a toothbrush.

 

[SBR Joe]

I had to do it twice and I have an 8pt cage in mine! I would rather paint my car with a toothbrush.

Howd your back feel after that?

 

[BlackStar]

ok well should you have to push the little piston on the slave cylinder back out or should it pop out and push the pedal back out?

 

[BrokenTsi]

Howd your back feel after that?

I had bruises on my hips from slumping over the door bar, .

 

[toofast82]

I'd be sure the pedal assembly is in good shape before going any further.
Very simple, go under the dash, locate where the rod for the clutch master attaches to the pedal. It will be above the gas pedal. Next push the pedal down with your hand and watch the rod on the master. It should move at the exact moment that you push the pedal, if it doesn't its bad
Clutch Pedeal Adjustment - Team Rip Engineering

After having done about 4-5 of them, it is one of the worst things you will ever have to do on the dsm.

 

[SBR Joe]

ok well should you have to push the little piston on the slave cylinder back out or should it pop out and push the pedal back out?

Im not sure im understanding what youre asking.

If youre asking if it should return to the depressed position on its own, yes, and that in turn will push the pedal back out.

 

[BlackStar]

UPDATE!!!!
So i changed my slave cylinder a couple days ago and the clutch worked ok (ish) for about half way around the block and then it seemed like I lost pressure for the pedal. since then it has gotten worse to the point where it doesnt really engage and i cant get it in any gear!. Also when i push the pedal in it makes a spinning grinding sound right where the motor and tranny bolt up.. I think Im at the point where im gonna tear the motor and tranny apart and see whats going on.....Unless anybodies got any ideas??? Thanks guys!

 

[BrokenTsi]

Sounds like its time for a new clutch. Perhaps a bent/broken disc or clutch spring.......