ABY Clutch Issues

[mcandmar]

Anybody got any ideas on what the issue is here?

The clutch on the avant was overly light and spongy when i bought it, then last night the pedal dropped to about 3 inches from the floor. It was still drivable, i could select a gear and drive home.

Step 1: I bled the clutch and it seemed ok for about 15 mins, then dropped to the floor again.

Step 2: Fitted a new master cylinder and bled again, was ok for the first few pumps, then dropped to the floor again.

Previous owner had a new clutch fitted a short time ago, and did say the clutch and gear change felt funny afterwards. Looking at the receipts they fitted a new dual mass flywheel, slave cylinder, and clutch.

The gearbox also has a bearing gone so i have to change that anyway. My spare 6speed has a new slave cyl, and release bearing fitted so i'm covered there.

My only worry is the new clutch, is it possible they fitted the wrong item? Or could the pressure plate have failed already? Unfortunately i don't have a spare one and would really to work out what the issue is first.

Any ideas please shout?

Thanks, Mark.

[vader s2]

aby clutch Issues

Anybody got any ideas on what the issue is here?

The clutch on the avant was overly light and spongy when i bought it, then last night the pedal dropped to about 3 inches from the floor. It was still drivable, i could select a gear and drive home.

Step 1: I bled the clutch and it seemed ok for about 15 mins, then dropped to the floor again.

Step 2: Fitted a new master cylinder and bled again, was ok for the first few pumps, then dropped to the floor again.

Previous owner had a new clutch fitted a short time ago, and did say the clutch and gear change felt funny afterwards. Looking at the receipts they fitted a new dual mass flywheel, slave cylinder, and clutch.

The gearbox also has a bearing gone so i have to change that anyway. My spare 6speed has a new slave cyl, and release bearing fitted so i'm covered there.

My only worry is the new clutch, is it possible they fitted the wrong item? Or could the pressure plate have failed already? Unfortunately i don't have a spare one and would really to work out what the issue is first.

Any ideas please shout?

Thanks, Mark.

hi mark. look at you slave cylinder. i had the same problem. pedal droping to the floor and sometimes hard to get into gear. we removed the slave cylindar to find the rubber seal had folded back on its self. the slave was new from audi. i would say the slave is worth looking at. hope you sort it out

cheers paul w

[quattrodude]

i also had the same prob, 1 day the pedel just sank and it was the slave cylinder in the end.

Good luck mate and hope you get it sorted

Lukas

[macspring]

Mark,

I'd bet on the slave cylinder, much easier to thoroughly check out first in advance of any thoughts of dropping the box?

Let us know either way.

Kind regards.

[Rusty]

I've heard that you can get teh slave out without dropping the box. The clutch system is pretty simple so it's the only thing left to change by the sounds of it. Good luck.

[slow2]

I've heard that you can get teh slave out without dropping the box. The clutch system is pretty simple so it's the only thing left to change by the sounds of it. Good luck.

your right, with a bit of a stuggle, some loss of skin and alot of bad words, you can
remove slave cylinder without dropping the gearbox.
when it comes to putting new slave cylinder back, you will find a new list of bad
words to say(loose some more skin) as you stuggle to complete a job that looks
so straight forward.

[mcandmar]

Got the gearbox out and it looks damp around the slave cyl from leaking fluid. Happy i found the problem now, thanks guys

Mark.

[Rusty]

your right, with a bit of a stuggle, some loss of skin and alot of bad words, you can
remove slave cylinder without dropping the gearbox.
when it comes to putting new slave cylinder back, you will find a new list of bad
words to say(loose some more skin) as you stuggle to complete a job that looks
so straight forward.

Ah, this was from a mechanic at an Audi specialist so I'm sure he's got a script written for this one. f*******c******s*******w********* etc. Something that a certain G Ramsey would be proud of

[mcandmar]

A few updates and observations

Got back to work on this today and fitted the new gearbox/slave cyl. One of the things bugging me about this issue was the fact the slave cyl was only a few years old. I noticed however that the slave cyl is whats best described as an aftermarket POS. It also explains why the bleed nipple is almost impossible to get at.

Pic1 is the unit in question, unfortunately i didn't take a picture of the top where somebody had to file it down to fit under the gear linkage mount. The bleed nipple is also located right above the clutch line. The only way to get at the bleeder is by removing the gear linkage first.

[mcandmar]

Pic2 is the new box with a genuine Audi slave cyl sourced through vag parts. The unit has SACHS proudly cast onto the side of it, and the bleed nipple extended out the back so you can actually get at it!

I think the moral of the story is don't use cheap spurious parts, its just not worth it.

[mcandmar]

Success, its all back in and bled and it feels perfect. Nice constant force and as smooth as butter

[Fat Audi 80]

Brilliant!

Isn't it nice when they work properly?

[europeanme]

sounds like familair symptoms.....my clutch gave up the ghost monday morning...

[smogthemog]

How do you actually remove the slave from the box?
Can I do it on my S6, realising it's gonna be a fiddly job, without removing the box - I REALLY don't want to do that! I just need to acertain if it's the master , Slave or internals

[mcandmar]

I'm told its possible but i had the gearbox out at the time. Its held in with one bolt just to the rear of the bleednipple/hyd line. When refitting it requires a bit of force to push the unit into the gearbox hole, then at the same time you have to push it onto the gearbox so the mounting bolt hole sits flush with the box. It will make sense when you see it but be prepared for some fun.