Clutch Failure/Problems

[Alistair E]

Pulled up at the lights last night alongside a new TT. Didn't get a good look at it before the lights changed but think it was an 'S'. It was dark but I could make out an A6 behind with what appeared to be slightly flaired arches. Looked like the TT was game, and he was. Took off from the lights side by side, nothing in it. Went for second, couldn't find it. A6 behind, which was actually an RS6, nearly ran into the back. Then I found that I couldn't find any gear. Pulled over and had a quick look around but there's not much you can check at the roadside.

Pressing the clutch pedal, it feels like the resistance of the pressure plate is there. Car goes into gear when the engine is off. No crunching sound when trying to get into gear with the car running. More of a whirring noise.

Got the car home, 1.5mile, by starting it in second gear until it caught and drove. Obviously, didn't try to change gear. Got into the drive, pressed the clutch but expected to have to stall it. It didn't. Didn't check to see if it was still trying to drive slightly. Switched off, started up, won't go into gear. Still the whirring noise.

Anybody got any suggestions? I'm guessing at master or slave cylinders but could it be something else.

Any advice gratefully received.

Thanks

Alistair

[Fat Audi 80]

Master Cylinder rod failure is most likely. Is the clutch action still very smooth or a bit "crunchy". Mine was crunchy when the master cylinder failed.

Have a look under the dash by hanging your legs over the drivers seat.You may need to remove the lower parcel shelf to see clearly. I have not done it, but you should be able to see the rod from the master cylinder where it actuates via the clutch pedal.

Good luck.

Cheers,

Steve.

[Alistair E]

Steve

Put my hand under the dash and could feel the rod moving when my daughter pressed the pedal. I've replaced in the past when it felt like the rod was buckling. Haven't had the cover off yet to look properly but my first impression is it's not that. Maybe wrong.

Alistair

[nip]

i had the same problem few years back, it was the pressure plate had collapsed mate

[S2central.net]

Sounds feasible to me... An unfortunate early bath for the S2 from the Wirral traffic light grand prix - Audi division

Spose you should be lucky for not getting rearended by a surprised RS6 cos of it. That would have been horrendous.

[Alistair E]

Paul

What sounds feasible, pressure plate collapse, master cylinder rod or something else?
You're right about the RS6, bit close. Was impressive when he got past and took off after the TT. Mind you, I was virtually stationery at the time. 1st time I've had the chance for a comparison, Grrrr.

Nip

were the symptoms the same in that, did it still feel like you were pressing the pressure plate? My clutch doesn't actually feel any different to normal.

Thanks

Alistair

[Fat Audi 80]

If the fingers have gone on the pressure plate and your master cylinder is still in good working order you will have a normal feeling clutch that just can't disengage.

Sounds like a gearbox off and new clutch job...

Cheers,

Steve.

[S2central.net]

Pressure plate collapse (or fubar'd DM flywheel)... I would think that failed master of slave hydraulics would have your clutch always engaged and therefore it should have stalled on the driveway as you say...

Uhhh but you must have had enough / intermittent engagement to give you any drive to limp home in 2nd. Odd one - you have 2 hours to get the gearbox out and report back with photos and findings - LOL !

Seriously though - good luck - this one is going be something silly or something expensive.

[nip]

Alistair i had same symptoms that you are having now, clutch pedal felt normal.

[Alistair E]

I must have some release of the pressure plate for it not to stall. Drive seems fine, no slipping. I suppose I could have a partial hydraulic failure which isn't fully depressing the pressure plate. Or, as nip said, it's pressure plate related. Not sure that the symptoms point towards the dm flywheel. Can't think how that would work, but then I haven't had the gearbox off before.

Anything else internal to the gearbox? Haven't got diagrams available at the mo to see how the slave moves the clutch release. Maybe something bent to stop it giving full movement? Fishing for answers at the moment but probably won't be able to look at it til Friday.

Alistair

[ericd]

try bleeding the clutch , also worth verifying you can get it into reverse, what kinda mileage you got and is it on original clutch as far as you know, anytime I've seen scenario you've described it's been the cheapest nastiest bit, the release bearing, sometimes you'll find the springs on the plate aren't broken or cracked they're just "tired", check the obvious before going further, cause it's a bit of a PITA to do (not the clutch just the dismantling and assembly), I'd happily pay somebody to do it, after doing mine about 4 years ago

[Acidburn]

Pulled up at the lights last night alongside a new TT. Didn't get a good look at it before the lights changed but think it was an 'S'. It was dark but I could make out an A6 behind with what appeared to be slightly flaired arches. Looked like the TT was game, and he was. Took off from the lights side by side, nothing in it. Went for second, couldn't find it. A6 behind, which was actually an RS6, nearly ran into the back. Then I found that I couldn't find any gear. Pulled over and had a quick look around but there's not much you can check at the roadside.

Pressing the clutch pedal, it feels like the resistance of the pressure plate is there. Car goes into gear when the engine is off. No crunching sound when trying to get into gear with the car running. More of a whirring noise.

Got the car home, 1.5mile, by starting it in second gear until it caught and drove. Obviously, didn't try to change gear. Got into the drive, pressed the clutch but expected to have to stall it. It didn't. Didn't check to see if it was still trying to drive slightly. Switched off, started up, won't go into gear. Still the whirring noise.

Anybody got any suggestions? I'm guessing at master or slave cylinders but could it be something else.

Any advice gratefully received.

Thanks

Alistair

I've got the same thing atm.

starts up in gear, drives fine but slips on boost in high gears now.
vibrating clutch pedal
can't change gear with engine running or get into gear.

drove the car to the lockup the other night to park it up, sounds like the clutch is gone on yours as well as mine.

[johne]

Had my clutch fail twice in a similar way, once at 75k miles and then again at 120k, went to overtake and couldn't get into gear. Clutch felt normal but actually wouldn't disengage so in my case engine would stall.

Fault in both cases was a specific failure in the pressure plate. The pressure plate fingers pivot on a set of rivets. Running around the outside of these rivets is a loop of wire, coat hanger diameter. This wire had failed where it's two ends were joined. That allowed the rivets to move just a fraction but that fraction was enough to change the pivot point for the fingers such that that slave cylinder no longer had enough travel to disengage the clutch.

Sorry, not much help, just a depressing message that means taking the engine or gearbox out. (I chose engine) Be interested to hear the outcome.

John

[curlyks2]

Pressing the clutch pedal, it feels like the resistance of the pressure plate is there. Car goes into gear when the engine is off. No crunching sound when trying to get into gear with the car running. More of a whirring noise.

Snap on the description.

Fault in both cases was a specific failure in the pressure plate.

Snap on this cause.

Mine went while trying to find a gear coming out of the chicane on the Bedford Autodrome back straight

Ck.

[Alistair E]

Not had chance to get to it yet, busy weekend. I fortunate that I bought an old N reg VW Transporter in the summer so at least I'm not off the road.
I must admit, the more I think about it, the more I think it's pressure plate or release bearing failure.

Still undecided as to what to do. Engine and gearbox out, or just gearbox. I'd like to take the engine out aswell as it could do with a clean up, sort out oil leaks, etc. Maybe even head off and a decoke. It's done 145k so it may not be a bad idea. Just not sure I want to start such a big job coming up to Christmas. My garage isn't big enough to get the car in but I have got room to work on anything I remove.

I've been doing a fair amount of forum searching but can't find a good guide on gearbox or engine removal. Found one that said disconnect everything, remove gearbox, fit new clutch, refit gearbox, reconnect everything.

What needs to be removed to pull the engine out through the front of the car. There's the obvious of bumper, crossmember & intercooler, radiator. Do the lights have to come out? Can I leave the inlet and exhaust manifolds attached. Don't really want to get so far then find I trying to remove bits from the engine whilst it's on the crane.

Another thing that swayed me towards engine removal was the opportunity to fit new rods (which I haven't bought yet). I'm looking to run 380-400bhp with whatever torque I can manage with that. It would be basically RS2 setup, turbo, e/manifold, injectors, intercooler. Still to decide on exhaust. I'm looking at the standard sachs clutch. Also unsure whether rods are really necessary. I've read many differing opinions so still not sure.

Any views advice gratefully received.

Alistair