300Tdi clutch slip (in fourth mainly)

**eddiec** · 8th November 2009, 04:31 PM

Hi all,

Just a quick diagnosis type question...

The clutch in our 96 300Tdi appears to be beginning to slip, especially in 4th gear (a little in five, not so much noticeably in the others). I'd picked up on this a month or two ago, but only on a trip down to the coast this weekend (with a full load of kids and camping gear) did it really become noticeable. That kind of slip where it feels like the engine gets a bit ahead of the rest of the car (especially on hills) and you have to slack off to let the revs and engine speed come back together.

Now I'm hoping this isn't a clutch on its way out, but am prepared that it could be. I'm just wondering if it could also be an adjustment issue as we have just had the master and slave cylinders replaced and I didn't notice the problem before that (at least, not as noticeably as now.)

Any ideas as to what else it could be, and whether it could just be a bad adjustment?

Many thanks,

Eddiec.

**Lucus** · 8th November 2009, 04:34 PM

clutch for sure mate

**BigJon** · 8th November 2009, 04:34 PM

It is either adjustment, a worn out clutch or contamination of the clutch (oil).

Is there free travel in the clutch pedal?

**Blknight.aus** · 8th November 2009, 05:42 PM

if its slipping its stuffed or soon will be, check the free play on the clutch pedal if theres free play on the pedal then its the plate.

**eddiec** · 8th November 2009, 07:40 PM

thanks fellas...

no free play on the pedal. since i've had the cylinders replaced it's been wonderfully tight... but this seems to have been the next recurring issue....

sigh.

back to the shop!

**Blknight.aus** · 8th November 2009, 07:42 PM

if theres no freeplay on the pedal theres a slight chance that the MC is not cycling properly there should be about 1 inch of movement at the pad of the pedal before the pushrod takes up on the cylinder.

**eddiec** · 8th November 2009, 07:47 PM

sorry - misunderstood the concept of 'free play'.... there probably is about an inch before it kicks in... so that sounds about right.

i'm not hugely surprised if it's the clutch going. it's the last item in the drivetrain that hasn't been replaced in recent memory!!

**slug_burner** · 8th November 2009, 08:22 PM

I had gbox rebuilt, when they put it back together the clutch slipped as you described. Went back for adjustment and have not had any further problems.

**eddiec** · 9th November 2009, 11:40 AM

thanks again... i may take it in for a diagnosis and in the hope that it's just an adjustment - but am prepared for the pain of a new clutch.

On a curious note - how hard is a clutch change in a 300Tdi. I've been rummaging the internet and seen people doing elemtns without completely dropping the box and instead removing the floor, tunnel, etc. I'm not overloaded with workshop tools and engine cranes so am wondering whether it's the sort of project to tackle at home... Is it relatively straightforward? Just aware that I'm already up for replacing shocks (and will do that at home), so am considering just a big Xmas break or getting those things done.

**Lucus** · 9th November 2009, 11:45 AM

IMHO if it was an adjustment issue the clutch would be inclined to slip in all gears not just 4th and occasionally 5th.

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