Clutch slipping, pedal adjustment?

fender22 · 9th April 2011, 01:16 PM

Clutch has been slipping for some months on my 93 200TDI.
Had the slave cylinder replaced a few weeks ago and there was fluid that had been leaking in the housing. Was marginally better after all that but it will still slip if I push the accelerator hard in forth or fifth gear.
I've pulled the housing plug out for a few days in case there's anymore fluid
in there but was reading in my repair manual that if the pedal isn't adjusted correctly can cause slipping. The clutch was only replaced about a year ago so shouldn't be anything majorly wrong with the clutch itself.

There's no play in the pedal at rest. Should I back off the stopper a bit to let it release more perhaps? Is that done under the dash at the pedal or in the engine well?

Is it ok to leave the case plug out apart from when going 4wding

**Bushie** · 10th April 2011, 07:34 AM

fender22 · 10th April 2011, 07:50 AM

Sorry, not overly mechanical :-(
Should there be some play in the clutch pedal? Sounds like there should be 6mm.
At the moment there is no play at all

If the clutch pedal wasn't adjusted properly in this way could it cause slippage, ie the
adjustment of the rod wasn't allowing the pedal to return fully "out"

Could the pedal "stop" bolt be stopping the clutch returning fully?

**harro** · 10th April 2011, 08:57 AM

Originally Posted by fender22

Sorry, not overly mechanical :-(
Should there be some play in the clutch pedal? Sounds like there should be 6mm.
At the moment there is no play at all

If the clutch pedal wasn't adjusted properly in this way could it cause slippage, ie the
adjustment of the rod wasn't allowing the pedal to return fully "out"

Could the pedal "stop" bolt be stopping the clutch returning fully?

You have pretty well got it spot on.
Note #7 on Bushies diagram, 6mm freeplay, easily adjusted with the nuts either side of the trunnion on the pushrod.
Put you finger in the housing and feel the pushrod, without any pressure on the pedal it should feel loose (small amount of sideways movement).
I have nearly 20mm freeplay and works fine.
Also important to set the correct pedal height! or as close as you can get

Cheers,
Paul.

fender22 · 11th April 2011, 09:42 AM

After deciding I was going to have a crack at adjusting the clutch pedal yesterday, before I got to it bugger me if I wasn't driving home last night and the clutch came good. The pedal felt different too. I got in the car this morning and the pedal went straight to the floor then seemed to come back to pressure and all was ok. The release of the clutch is now a lot sooner (releases closer to the floor) also and now there is 5 or 6 mm freeplay in the clutch pedal at rest. Drives as good as gold now. Was a mongrel with the clutch slipping.

My first thought was that when the slave cylinder was replaced a month ago he
mustn't have bled it properly and it's finally burped out an air bubble or something out of the line
but I would have thought with an air bubble in the line it would have had less pressure on the pedal / clutch plate rather than too much?

**JDNSW** · 11th April 2011, 11:38 AM

I think I would be looking to make sure the adjusting nuts on the master cylinder pushrod are not loose, allowing the free play to change. Another possibility would be that something is stopping the pedal from coming right up, and is now no longer doing so.

John

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