Clutch or hydraulics?

[MrAudi2017]

Good evening ladies and gents...

Right so I had a situation a couple weeks ago, basically driving home from work the clutch went on my 1.8t, no slipping or anything but basically I could push my foot to the floor and couldn't get any gears. If I'm honest the bite point was slowly getting lower for a while and I didn't think anything of it. No I diagnosed it as a master cylinder problem and decided to change both slave and master cylinder (as it's the on gearbox type of slave not concentric) however I'm not sure if I'm having a hydraulic issue or a pressure plate issue? Since changing them both and what I assume is bleeding the system I've still not got a clutch and the pedal isn't returning to where it should be.... I've sent nearly a litre of break fluid into the system but only had maybe 100ml come out of the other end?

So I'm at a loss, one where could this outer of fluid have gone and 2 what's he chances that the clutch pressure plate has just caved in and I'm gonna have to be changing that?

Also I've been looking it up and there seems to be 2 different sizes of clutch for sale, 220 and 228mm however it doesn't give me any clue of which one I should be buying...

Any help would be appreciated!

2001 A3 sport 1.8t (is a facelift one)

 

[Stuart B]

have you checked it's not coming out of a brake caliper - the clutch take off is from above the brake? as I found with my faulty clutch slave cylinder inside the bell housing - the fluid must be going somewhere.

 

[MrAudi2017]

have you checked it's not coming out of a brake caliper - the clutch take off is from above the brake? as I found with my faulty clutch slave cylinder inside the bell housing - the fluid must be going somewhere.

M
Yeah no leaks in the system... to be honest since I've changed both the slave and the master cylinder the fluid seems to be coming out as much as it's going in...

But I do feel like I'm missing something here... I mean since this has happened when the clutch is open (off pedal) there's a nice noise which suggests the bearing is scraping against something as it goes away as soon as I rest my foot on the pedal. But since changing both the cylinders I've got less pedal feel and the pedal isn't returning all the way up? I've bled the system loads, and to the workshop manual... so I'm at a loss... I am litterally bored with catching the train to work now after the recent terrific weather patterns

 

[Stuart B]

you need to find out where the fluid is going - are you sure the slave cylinder is outside the gearbox? I thought my bleed nipple on the gearbox was the slave cylinder but it is on the release bearing on an S3 eventually the brake fluid started leaking out of the bell housing. but the clutch hydraulic circuit is pretty small, RES-> MASTER -> round box (which apparently can leak) -> to bell-housing

are you still having to top it up? even with my broken slave cylinder I could eventually get pressure in the pedal but it was dead again the next day.

 

[MrAudi2017]

you need to find out where the fluid is going - are you sure the slave cylinder is outside the gearbox? I thought my bleed nipple on the gearbox was the slave cylinder but it is on the release bearing on an S3 eventually the brake fluid started leaking out of the bell housing. but the clutch hydraulic circuit is pretty small, RES-> MASTER -> round box (which apparently can leak) -> to bell-housing

are you still having to top it up? even with my broken slave cylinder I could eventually get pressure in the pedal but it was dead again the next day.

Nope, the level is remaining correct there's no fluid under the car or in the wheels (suggesting brake fluid leak)

It's also a 2wd one so yeah the slave is deffinatly not a concentric one...

I'm kinda reserved something is wrong with the actual clutch here, it's been bled thoroughly new master and new slave cylinders... so my last resort is the pressure plate is knackered or the push fork is bent...

 

[Stuart B]

I thought you said you have put 1 litre in the top and only got 100ml out of the bottom? or did you mean you have bled it with 1litre and it has not improved?

 

[MrAudi2017]

I thought you said you have put 1 litre in the top and only got 100ml out of the bottom? or did you mean you have bled it with 1litre and it has not improved?

Well it started off as that... but when I went back to it and tried to bleed the system again what went in come out the other end...

 

[Stuart B]

I had to pump the clutch about 80 times to build up the pressure, using my hand to start with then after about every 20 let out the pressure. you are supposed to leave the pedal down when you crack the slave nipple, but I found it just needed doing all again then, as it draws the pedal to the floor.

 

[ben4866]

Clutch fork!! They fatigue over time and split/bend giving the exact symptoms your having.

They're quite cheap from the dealers.

 

[MrAudi2017]

Clutch fork!! They fatigue over time and split/bend giving the exact symptoms your having.

They're quite cheap from the dealers.

Oh goodie.... ok so I'll make sure I will order one of those too thank for letting me know

 

[MrAudi2017]

Round of applause to ben4866 who give me the clutch fork! That would be the issue I have! That and 2 rounded off drive shaft bolts thanks to some thunder c*n*