Hi all, bit of an issue with my brothers car. its a tt.

 

It has recently had a new clutch installed and has been run in.

 

It was slipping but he adjusted the clutch pedal rod and it has been running nicely since. But the other day it has completely locked him out of the gears not selecting anything. We bled the clutch system an as far as we are aware, all the air is out and its engaging and selecting gears ( albeit ) a bit notchy. But the issue now is that the pedal has a few inches of free play where there is no resistance at all and its engaging pretty close to the floor. It does not feell quite right. We dont want to adjust the rod too far the other way to cause slipping again. If the engine is off and you pump the pedal pressure builds and it feels about right. then start the engine and the pedal drops nearly a third and and will not get to the same pressure as before... slave cylinder??? air????. Any ideas?

 

Cheers

I have EXACTLY the same problem - I am taking it to Jeff's in the morning to get it looked at and will report back.

 

Makes smooth changing very difficult - If anyone can point us in the right direction I would appreciate it.

Sounds like the problem i was having also, and in a way still have! The clutch pedal was biting on the floor at first and when it was bled it felt fine until the engine was turned on and then it disappeared again. I got the master/slave cylinder replaced with a new one as well as a new clutch line. The garage also removed the pedal box and readjusted the servo link back to where it should have been. The clutch pedal is a lot better but i find gearchanges are quite stiff and not as smooth as they should be especially after the car heats up or you are stop/starting around town. I have an RPS carbon clutch and it almost feels like it is on or off with no in between when pulling away. When i get the Z back from the bodyshop i was going to try and find a garage which specialises in aftermarket clutches if such a thing exists and let them have a look at it.

my brother had the issue of very stiff gear selection on the box. to sort that he took the plastics off around the gear stick. That will expose the gear stick pivot. under that there is a nut and bolt underneath horizontally which connects the stick to the selecting rod undo that slightly and it will free up the stiffness. To do it he used a quater drive ratcher and a 12mm ring spanner i think. a little bit fiddly

If the engine is off and i just go through the gears they go in perfect, it is only when the engine is running that they stiffen up almost like the clutch isn't engaging properly.

when the engine is on,

 

air is sent from the balance bar to the clutch pedal, so it makes operating the clutch easier.

 

 

 

when i put my clutch back together after an auto to manual conversion,

 

 

the clutch gave re-sistance when engine off, but none when on.

 

 

bled it a million times, but in the end just needed to adjust the clutch, to the maximum it goes.

 

still doesnt feel like it used to, but operates the car fine & doesnt slip, and bighting point is nice and low to the floor

I've got this exact same problem...very crunchy changes despite the clutch pedal being on the floor.

 

I had a conversion done by Jeff and fitted an RPS Max clutch. Didn't have any problems to start with but it quickly developed and seems to get worse as the engine warms up...downchanging expecially..I sometimes have to really force it into gear...

dito, biting point near floor level, bleed and adjusted, maybe its working as intended lol

All seem to have the same issues. The down shifts are sometimes hard to get in, The clutch free play is annoyingly large, the bite is low... but it doesnt slip.

I had this, i got Jimmer to rebleed my system and now its all working happy again :), funny enough it was a RPS clutch as well XD

when you have adjusted the clutch have you wound the 2 switches back first, then adjusted teh pedal, then wound the switches back till they just touch?

if you dont then the switches stop the pedal getting a full push on the master cylinder

until they just touch the pedal or until the switches are depressed and not tightened?

until they just touch the pedal or until the switches are depressed and not tightened?

 

sorry , i meant so they are just depressed fully, but the switch body is not stopping the pedal travel

strange, my brother fully adjusted the clutch pedal and switch ( there was only one. and only one stopper on one side of the pedal ) as per instruction, and by following a walk through... its worked lovely. But today its gone back to being a bit harder to get into gear ?? the fluid level does not look like its dropped but but could this be a small leak somewhere not allowing enough pressure to fully disengage the clutch ?

Edited December 18, 200915 yr by ZX-TT

you need to confirm if the clutch is dis engageing completly.

then you can make a correct plan to diagnos it and fix the issues.