clutch master or slave, how do i pin point

That was my time poor solution, takes about an hour to machine it up in a good machine shop if you dont mind it rough.

an even rougher solution is to use a piece of inch rod and just machine up one end as a ball with a pin and the other to fit the SC.

Its a better fix than the old "drive without a clutch" routine but you're right its a "get you home" not "go on tour" fix.

if all goes well this weekend for me and you cant get it in anywhere else line up a 3 man crew for next friday arvo, I'll load the gear turn up and we'll do a 6 hour clutch change.

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Originally Posted by Blknight.aus

That was my time poor solution, takes about an hour to machine it up in a good machine shop if you dont mind it rough.

an even rougher solution is to use a piece of inch rod and just machine up one end as a ball with a pin and the other to fit the SC.

Its a better fix than the old "drive without a clutch" routine but you're right its a "get you home" not "go on tour" fix.

if all goes well this weekend for me and you cant get it in anywhere else line up a 3 man crew for next friday arvo, I'll load the gear turn up and we'll do a 6 hour clutch change.

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Thanks dave but she is booked in at British Offroad.

my bad, I thought you were going to see them tomorrow to see if you could get in...

where are you headed on the trip?

Shame you don't have the time 'Weeds', Daves mod is better than the original setup.

Deano :)

Do the punch through scenarios only happen on the pressed metal release forks ? When I was having a clutch issue on my Td5 I thought this was the problem but inspecting through the slave hole with a snakescope I found a nice cast lump of a throw out fork like this one
https://www.aulro.com/afvb/images/im...013/03/535.jpg
would it not be wise to retrofit one of these into a Tdi or do they still suffer punch thru issues?

nope the cast fork is the go, theres plenty of upgrades to do to the pressed one.

the cast fork occasionally falls over by busting the thrust bearing, stuffing the push rod ro cracking the plastic cum in the center and falling off of the ball.

May I also suggest you change the flexible hose that runs from the master cylinder line to the slave cylinder. I had trouble with this bulging and losing pressure. It is a cheap part and while you are down there it pays to do it.

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Originally Posted by Chenz

May I also suggest you change the flexible hose that runs from the master cylinder line to the slave cylinder. I had trouble with this bulging and losing pressure. It is a cheap part and while you are down there it pays to do it.

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The workshop manual recommends changing all rubber brake components at intervals of no more than 4 years IIRC; presumably clutch rubbers wear similarly.