Help - Clutch Questions - 110

**Michael2** · 6th January 2009, 09:15 PM

Problem : Can't select gears in 300Tdi 110

History : Replaced a weeping Clutch master Cyl 100km ago.

Diagnostics : I can start it in gear & drive, there's some residual clutch effort which assists in gear changes - but not always.

I checked the level (ok),
I re-bled the clutch and with my wife pressing on the clutch, I can hear the clutch plate moving in the bellhousing (when I'm under the car bleeding it).

Still, can't select a gear!!

I doubt it's a fork, as I can still hear the clutch move - but could it be?

is there any thing else to look at do. It just stopped working suddenly without any noise, as I came off the FWY, but everything was working well with the old master cyl and with the new one. The Master Cyl isn't leaking at the rod (externally).

I suppose it could be an internally leaking master cyl, but it was new, so I hope not.

Any ideas?

Thanks in advance, Michael

**Blknight.aus** · 6th January 2009, 10:12 PM

are you sure its the clutch moving and not just the asisst spring in the slave cylinder? or the fork scraping on the pivot becuase its bent up....

drop the slave off and manually check its travel and how it moves with some resistance applied to it (manually hold it in while you have someone carefully push the clutch in...

if its not the slave or the master recirulating any fault you have requires the removal of the box or the donk.

**BigJon** · 6th January 2009, 10:28 PM

Sounds like the pivot through the fork to me...

**Michael2** · 6th January 2009, 10:32 PM

with somemore flushing, it now engages gears with the motor off (was baulking at that earlier), but still won't engage with the motor on.

I removed the slave and it didn't seem to be leaking, the fork seemed ok by sticking a finger in the slave hole, but that's hardly diagnostic.

Everyones now in bed, so I'll have to have someone depress the clutch with the slave off tomorrow and feel for resistance.

**Michael2** · 6th January 2009, 10:33 PM

Originally Posted by BigJon

Sounds like the pivot through the fork to me...

would that happen quickly & silently?

**BigJon** · 6th January 2009, 10:38 PM

I have seen it happen like that.

Customer put her foot on the clutch at traffic lights and the pedal went part way and went hard.

When the Disco was brought in (essentially the same clutch setup), there was no noise, no leaks, but an odd feeling, hard pedal. The clutch would slightly disengage, but not fully.

Removal of the gearbox showed fork failure.

Sorry to be the bearer of bad news, but it could well be what yours has done.

**Michael2** · 6th January 2009, 11:15 PM

Well, the clutch doesn't feel hard, I've rebuilt the old master cyl, and will do the test on the slave in the morning. If the master's leaking, I'll be able to replace it immediately. Failing that, I'll need to find a friend with a flat concrete driveway.

What's easier, gearbox or engine removal? On the SIII it was always g/box removal, but when i did the gearbox on the RR I noticed just how much heavier & more difficult it was. I suppose there's not that much to disconnect on a Tdi, so I'm thinking motor removal. Informed opinions would be greatly apprecaited though.

Michael

**Blknight.aus** · 7th January 2009, 06:06 AM

for me its 50/50 but it depends on what gear you have access to to do the work.

engine cranes are usually easier to find that places with 2 post hoists and high lift transmission jacks.

**Michael2** · 7th January 2009, 06:51 AM

okay, I haven't started pulling the slave out yet, but this is what I get :

normal pedal feel

able to engage gears with the engine off

then able to engage gears smoothly with normal clutch pedal

unable to engage gears with the motor running.

no sinister mechanical sounds

**weeds** · 7th January 2009, 07:02 AM

i had similar woes at cooma last year

all of a sudden i could not select first gear with the motor running, i could select first gear with the motor off and than start the motor. when i started the motor i could feel a slight grabbing of the flywheel and i could still move off normally, i than had to change gears without using the clutch and rely on revs.....all the way back to brisbane

we thought it may have been the pivot but it ended up being a dislodges spring in the clutch plate

http://www.aulro.com/afvb/technical-...nce-cooma.html

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