Clutch not disengaging fully

[G60Rallye]

Since I got the engine running I have had an issue with the clutch not fully disengaging. It will almost clear but wont take a gear when the engine is running. Its a 20v engine with an 016 box. Billet steel flywheel from Aelred. Helix pressure plate and paddle drive plate.

I had read a while ago somebody else had issues when using Aelred's billet flywheel because it was thinner. To compensate they used a longer slave cylinder rod. I have tried this on mine but it hasn't made any difference.

I pulled the gearbox off today to have a look inside and I cant see anything wrong. Then I decided to see what the stroke of slave cylinder was. So I pushed the slave all the way down and a mate pressed the clutch to the floor. It only strokes 20mm. The overall travel of the slave is 55mm, so it has a lot more to give.

So my conclusion is that the master cylinder cant displace enough fluid, and its not quite got enough travel to fully disengage the cover plate? 20mm sounds enough but with the release bearing being on a pivot it will only give 10mm to the release bearing? I dont know if anybody has had similar issues? The only option thats left I think is to get a bigger master cylinder?

Just to add both the slave and master are brand new audi ur quattro ones and are bled properly. It would be very useful if anybody had an data for a lhd ur quattro master cylinder so i knew how much fluid it displaced?

[WabTheKing]

I had this issue with my v8 with a fidanza flywheel and spec 3 clutch. Extended the push rod by 15mm and this fixed it. Have you thought about maybe converting to a centrifugal slave? Think tilton do one?

[jsmith14]

Perhaps it's not completely bled? Sometimes it's a actual PITA to hemorrhage the clutch system because the liquid consumption is relatively higher in the master cylinder reservoir. I had something identical but the diagram rises smashed on my clutch system and it would still launch, but since it was only on one aspect it didn't launch completely. It limited the disc up and the same concern you are having was what I was having. you have more Audi repair questions you could use some of this repair guides on auto md.

[Bullysteeth]

does yours have an adjustable rod on the pedal between it and the master, i had to back mine off as it had to much travel after fitting a new clutch, maybe wind yours up, (just a thought)

[G60Rallye]

Thanks for the ideas. Mine does have the adjustable rod and it was adjusted for maximum travel. I have bought a much larger tilton master cylinder and its all sorted.