Clutch Help!!

trailpimp33 · 01-24-2009, 05:14 PM

I have an 83 n/a that I am working on. Here is the issue, I thought that maybe the master or slave were going out as the pedal would travel down about 2" with only a tap of the foot and you could then feel it make contact with the master, then it would not return all the way, stopping at the 2" mark. I checked the master, slave, and lines for any signs of leakage with none to be found. When I checked the floorboard for fluid I also found NOTHING. What I did notice though is that the plunger for the master is NOT making contact with the piston until it goes through that first 2" (at the pedal not the master) of travel. The piston seats against the c-clip, it just seems as if the plunger is not long enough or there is something missing at the end of the plunger. I have the plunger rod adjusted as far out as it can go so that is not the issue. Should there be anything at the master side of the plunger or does it simply rest in that bore?

phoenix_iii · 01-24-2009, 08:48 PM

Original parts? Miles? Are you having any actual problem?

Gary2397 · 01-24-2009, 09:54 PM

You can try to bleed the clucth system if that works for now.
If you see brake fluid leaking around floorboard then it is too late.

May be it is warning sign for master clutch failure.

HondaDustR · 01-24-2009, 10:13 PM

There is nothing that connects to the master cylinder. It's just the rod with the rounded end that just sits inside the cup shaped recess on the MC piston and should be just barely touching it. If you pull the rubber dust boot off, you should see the piston fully retracted right up against an internal C-clip on the end of the bore closest to the pedal. If it's further inside, either some springs are broken, the piston is binding, and/or there's a bunch of air in the system that prevents the clutch pressure on the slave from forcing the master piston back, but it has a pretty heavy spring inside that should return the piston on it's own.

trailpimp33 · 01-24-2009, 11:42 PM

The piston seats against the c-clip and retracts no problem, that is what is throwing me. The master looks good, I am starting to get suspicious that the PO used a part from some other car.(non 944) The master looks good, just that plunger seems like it is not long enough, or the master does not come through the fire wall far enough.
Any other ideas???

Anyone have a spare clevis and plunger from an old swap laying around?

speedracing944 · speedracing944's Garage

you need to bleed your clutch. Lift the rear high in the air and use a pressure bleeder.

Speedy

HondaDustR · 01-25-2009, 08:25 AM

Guys, it sounds like there's a mechanical discrepancy here. I'm not sure air in the system is the problem just yet. If the actuating rod doesn't even reach the MC properly, it's not going to work, bled or not.

Do you have a picture to show exactly what's going on? It could be a wrong part somewhere.

zedsn · 01-25-2009, 08:46 AM

There is adjustment on the rod and before the rod there is a spring. Do you have both of these?

trailpimp33 · 01-25-2009, 07:16 PM

The rod is adjusted out as far as it will go, and yet still does not make contact with the pocket in the piston until the clutch is depressed a bit. The master and slave do NOT need to be bled, the piston in the master is bottomed out on the c-clip. I will try and get some photos tomorrow.
zedsn, what spring are you talking about? On my car there is the pedal, to which the clevis is attached, then the rod which is threaded in the clevis, and the rod then makes contact with the piston in the master.

zedsn · 01-26-2009, 02:58 AM

Hi, above the rod higher up on the other side is a pre load spring. Is yours there? Get yourself a Haynes 944 shop manual and it gets into a little detail on adjustment.

trailpimp33 · 01-29-2009, 06:52 PM

Well, I found out the problem...

Cracked and bulged firewall!!

Anyone have a good fix for this one??

SuperXRAY · 01-29-2009, 07:33 PM

Ouch. Isn't that master cylinder like, way up there?