Mark P

After having a clutch install performed, my clutch pedal travel now does not go to the floor like it used to. Instead, about 75% of the way down, I am feeling (or so I believe) that the throw-out bearing is hitting the 3 "bottom-out" fingers on the pressure plate. If I press more, there's significant resistnace. I don't believe this to be a clutch/pressure plate issue, but rather related to the hydraulics and mechanics of the slave cylinder. I believe it is now pressing in further than it used to. I was wondering if there was a spacer that holds the slave cylinder out a bit, and if that wasn't put back in during reinstall, maybe now the slave cylinder is in further than it should be.

Can anyone with knowledge or ETKA lend a hand?

XCCESS

When I put my back together, I didn't see any spacer with new clutch slave cylinder

Imolavirus@BuehnEngineering

nope, no spacer afaik

SAC-CA-GTI

No, no spacer...just put one in last week.

Mark P

How else could the cylinder be pushing more than before? I haven't bled the system yet, so maybe that's in order.

Also, when I first got into the car after the swap, I pushed in the clutch and the pedal stayed down. I had to put my foot behind it and pull it back up then it worked fine. Definitely seems hydraulic related. For this clutch install, I didn't replace the throw-out bearing (it was recently replaced beforehand), so that didn't change.

Hmmmm

Imolavirus@BuehnEngineering

it needs to be bled. did they disconnect the lines when they did the clutch install?

Mark P

no they did not, just had the slave hanging there

GT28RedS4

held there with a skimpy 8mm bolt and metal clip.

Definately no spacer for the slave, but it does slide into a bracket with a slot, although difficult to reinstall bracket if the slave is not in correct position so I would doubt that is your case here.

Mark P

Thanks Mark - It's a SPEC PP and Hybrid Stg2/3 disc. Wihtout getting into it too much, I did two installs within 10days (anyone is welcome to tell me "I told you so"). The first install had issues with disengaging. The throwout bearing was replaced at this time (and then retained for the 2nd isntall). 10 days later and less than 500 miles, I replaced that with a new SPEC PP and Hybrid Stg2/3 disc. This time I had no disengement issues, but I noticed this travel issue. The clutch engages/disengages on the high side, and now has 2000+ miles on it and I am very happy with it, except for the travel issue. All along, the same flywheel (OEM) has been in there. Before either of these two clutches, I had a SPEC (stg2) clutch as well. It seems very unlikely that only on this last one could there be something wrong with the pressure plate - that just doesn't seem likely. Instead, it seems related to the slave, bearing hinge/mechanism, etc.

This shot is from when we first pulled it apart (TO bearing from Stg2 clutch still in photo)
<img src="http://ctny.audiworld.com/mark/s4/clutch/stg23install/images/DSC01485.jpg">

Here's pics from the first Stg2/3 install:
<a href="http://ctny.audiworld.com/mark/s4/clutch/stg23install/index.htm">http://ctny.audiworld.com/mark/s4/clutch/stg23install/index.htm</a>

And then the 2nd (current) install:
<a href="http://ctny.audiworld.com/mark/s4/clutch/stg23install2/index.htm">http://ctny.audiworld.com/mark/s4/clutch/stg23install2/index.htm</a>

GT28RedS4

are losing me a little. Sorry for being a little slow on this one but I can not comprehend all the changes/hardware that just took place in the 10 day timeline.

1. Prior to any work, original spec clutch was failing?
2. You then installed a new PP and it was faulty because of dis-engaugement? At same time of first install you replaced the TO Bearing? Elaborate on that, was new TO Bearing thicker than OEM? From teh pics it looks OEM because it has the black anti-friction cap on it.
3. The final PP that is currently in, is that a replacement for the 10 day prior install?

Sorry just want to help.