HELP! finished clutch change but pedal doesn't work

[mattatk]

Dear All,
Just finished replacing my clutch (disc, pressure plate, pilot bearing, throwout bearing & arm). Did the bleed as per the procedure with the pedal fully depressed...
Now when I start the car the clutch pedal stays stuck down or if I pull it up, it springs to the fully up position. With the pedal on the floor & engine running, the gear lever resists putting it into gear.
Can anyone shed some light into my dilemma?
Thanks in advance.
Matt

[dad911]

Are you sure the end of the arm that snaps into the spring was in properly? I almost got it wrong the first time.

Perhaps you can see in with a mirror by removing the slave cylinder.

Is it possible the clutch pedal was pressed while the trans was out of the car? I did that once in a 964 and it pushed the center out of the slave cylinder.

[mattatk]

Spring was clipped onto ball in transmission. I definitely didn't push the clutch pedal until bleeding.
The only unusual thing was it was very difficult to install the slave cylinder. I tried once & felt resistance, checked the manual & it stated that the bleed valve needs to be open. So I opened the valve & managed to get the slave in with lots of shoving(?) Could that be the prob?
I feel as though it is a hydraulic issue as there is no feel to pedal & no response (?) from it.

[dad911]

I haven't done mine yet, I'll be putting the engine back in this weekend

Right now, my engine/trans are out of car and bolted together. If I reach in where the slave cylinder connects, I can feel the where the arm receives the plunger centered, and about 1-1/2 inched back.

I would probably pop off the slave cylinder, and make sure all is well mechanically. You would have no pedal if the plunger misses, or popped out of the cylinder.

Did you bleed it by pumping or with a pressure bleeder?
When you opened the valve and pushed the cylinder in, did fluid come out?

[mattatk]

Firstly, thanks for the replies, most appreciated!
When I fitted the slave with the bleeder open, a small amount of fluid (maybe 10ml?) came out.
Bled with a pressure bleeder & clutch pedal depressed. Having said that, when I pushed the pedal in prior to bleeding, it went to the floor & happily stayed there. Last time I had to lock it down (as per the manual) with a bit of wood.
I'll bleed again, then pull the slave & inspect it. I'll try with a mirror to look into the cavity for the cylinder.

[mattatk]

Tried to bleed again & was surprised to see no fluid come out of the bleeder at 20psi (motive bleeder on reservoir) & clutch pedal in/depressed. Deduced that master cylinder is not porting the fluid down to the slave (bleeder) due to either failure &/or leak or blockage. No sign of any leaks, so I tried the easy way out, pumped the clutch pedal during the process. Bleed then proceeded successfully, maybe cleared the blockage or maybe an intermittent operation of master cylinder? Anyway the pedal doesn't come all the way up without assistance but has feel, so I'll bleed it again tomorrow a couple of times & see if I can get it working sufficiently (at least until I order & receive a new master cylinder!)

[Wayne 962]

I think you're on the right track. As I mention in the new book, the pressure bleeder is a good tool, but I also recommend pedal pushing as well, as sometimes there are issues with the pressure bleeder. Bleed the system both ways to make sure that you get all the air out of the system. I'm pretty sure that this is an air-in-the-system type of problem that will be easily solved once you rebleed. In general, I don't recommend opening the slave cylinder bleed valve, as that will cause potential issues like these.

-Wayne

[a1ajfredj]

This problem solution continues under 'Not the clutch again!' thread.