Clutch problem

[Gordon Rankin]

My clutch is losing fluid somewhere. Pedal will go all the way to the floor without engaging but can be pulled up and then engage, Pedal engages close to the floor. Feels as if a little hydralic pressure then seems to have plenty of pressure.. What gives??

[adrian jaye]

clutch master cylinder ??
leaks, what checks have you done so far ???

Ade

[AFJuvat]

Your master\slave\or the line that connects the two are leaking.

Look behind the clutch pedal and see if you can see brake fluid dripping out of the master.

Otherwise, look for a leak under the car.

AFJuvat

[powerhan]

I just found out that my clutch has the same problem. My car is parked at the local Church now. Could you please tell me what should I do next? Is it really difficult to fix or replace the part? If I bring it or tow it to the repair shop, how much am I looking at?

[Gordon Rankin]

My problem is solved. The clutch master cylinder was leaking, Found brake fliud above clutch pedal and in my carpet. Replaced same.Cost for cylinder was 65.00.

[SoCal Driver]

Now the fire wall is over flexing/cracked around the clutch master.

[Gordon Rankin]

OK Hugh.. How do we (you) solve that problem??
BTW, thanks for replacing that clutch cylinder for me..

Originally posted by SoCal Driver
Now the fire wall is over flexing/cracked around the clutch master.

[bigyagi]

hmm, i replaced my clutch master about a year ago. i seem to have a water leak, that is allowing water to get at the connectors behind the fuseboard/relays. after reading hugh's comments, it looks like this is a fairly common complaint?

[Panzer909]

Ahhhhh yes. You can tell its winter time.

Time for another round of clutch master/slave cylinder failures. This was a downright spooky phenomenon last winter. Heck, there must have been 20 guys on this board that had this happen between December and late February. I wonder who's gonna draw the short straw next?

[SoCal Driver]

Originally posted by Gordon Rankin
OK Hugh.. How do we (you) solve that problem??
BTW, thanks for replacing that clutch cylinder for me..

Jack up the radiator cap and drive a 951 under it.

Other wise I think somer serious welding. Possibly even a replacement section out of a trashed 944.

[powerhan]

Atlanta was cold in the morning last couple of days. I think that's what caused the leaking problem. Sounds like I have to tow the car at home and look under before I order parts. I saw one on Ebay for $70 Clutch Master Cylinder and $60 for the slave cylinder. Is a slave cylinder easy to rebuild with Pelican rebuild kit? Gordon, I didn't see any fluid from my carpet at all. However, my clutch padel is pushed all the way in and feels like there is nothing connected to the master cylinder. I can pull it out, but if I press it, it goes down to the floor right away.

[Britwrench]

To repair the cracked firewall, remove the clutch master cylinder and move all the wiring out of the way. make up a steel plate to fit neatly over the biggest area you can and get it tack welded on, put a couple of bolts to also secure it and refit the master cylinder. Not easy, but can be done.

[SoCal Driver]

I think jacking up the radiator cap is easier.

[bigyagi]

jeez, i'm really confused now! how the hell can the firewall crack so easily? i was thinking that maybe the gasket was at fault, but for the life of me, i dont understand how the firewall can be at risk of damage. unless it has all the properties of a chocolate fire-guard!!
well, i cant do much now, as its really turned cold, and i dont have heating in my garage, so it will have to wait until around march/april! i guess when i take the fuse box/relay board out, i will get a much better idea, of what is happenning in there! i can make a plate to fit the area no problem, and welding it is no prob. i just dont get it!
any insight please?

[Gordon Rankin]

Bigyaki,
Hugh and Britwrench are talking about MY car needing a sheet of steel, not yours. Most likely yours is fine,,,

And if there I had something else to place under that radiator cap, I do would it in a flash, Hugh!!!!

[Gordon Rankin]

Britwrench, have you actually done this ?

Originally posted by Britwrench
To repair the cracked firewall, remove the clutch master cylinder and move all the wiring out of the way. make up a steel plate to fit neatly over the biggest area you can and get it tack welded on, put a couple of bolts to also secure it and refit the master cylinder. Not easy, but can be done.

AND
What thickness of steel is sufficient?

[Britwrench]

Use something thick enough that you can bend to form the shape. All it is really doing is holding the crack together. Go down to a metal wholesaler and see what they have in stock. This is not an unknown problem but I've only seen a couple in the last few years. Yes, we've done the repair, I believe the last one was actually a 944S2 cab.
I have no idea why it happens, but judging by the crap design of my Audi clutch pedal linkage assembly and consequently cracked firewall I assume it is because someone, somewhere and probably in a design office close to the middle of a European country didn't understand what they were doing.......the same thing happens to Golfs too....

[Gordon Rankin]

Thanks!

Originally posted by Britwrench
Use something thick enough that you can bend to form the shape. All it is really doing is holding the crack together. Go down to a metal wholesaler and see what they have in stock. This is not an unknown problem but I've only seen a couple in the last few years. Yes, we've done the repair, I believe the last one was actually a 944S2 cab.
I have no idea why it happens, but judging by the crap design of my Audi clutch pedal linkage assembly and consequently cracked firewall I assume it is because someone, somewhere and probably in a design office close to the middle of a European country didn't understand what they were doing.......the same thing happens to Golfs too....

[SoCal Driver]

16 gauge. Still would be a pain. Just can smell all that old brake fluid burning off.

[SoCal Driver]

Originally posted by bigyagi
hmm, i replaced my clutch master about a year ago. i seem to have a water leak, that is allowing water to get at the connectors behind the fuseboard/relays. after reading hugh's comments, it looks like this is a fairly common complaint?

Gordon also had a water leak in that area but it was a blanked off hole in the "tray" area that was leaking. Used a slug from a j-box and a bunch of silicone to seal it.