Clutch Problem

[J0Xd4E]

Hi all,

I've recently developed an issue with the clutch on my 2.5 TDI California exclusive. During a drive last week the "bite" point of the clutch seemed to move further and further away and gear changes become harder, now there is no pressure to the clutch at all. A bit of googling seems to suggest that this might be a cylinder issue. My local garage who I trust and are very good can't get the van high enough on the ramps due to it's height to get at the clutch. The question I had was, does this sound like a cylinder issue and if so do you know if they are external on the T4? If so, they can fix, if not I'll need to find somewhere else.

 

[jts46]

Just had the DMF and clutch replaced on my T5, 2.5 TDI, 5 pot engine. I had done 127,000 miles.
What mileage has yours done?

John

 

[J0Xd4E]

about 134,000

 

[jts46]

I'm no expert but it sounds to me like the clutch

John

 

[TwentyOneThirtyFive]

Thought clutch on LHD T4s was cable. It's hydrolic on RHD.

 

[mrcheesbrough]

Hello there. This does sound like a clutch cylinder problem. From what I understand it's an internal part on certain models, particularly the 102 and 150 TDIs, and external on the 88 TDI. Most garages will advised to change it at the same time as fitting a new clutch. First thing to check though is the fluid level - this is the same reservoir as the brake fluid.

 

[jts46]

As i said i am no expert

John

 

[J0Xd4E]

Thanks for that, looks like fluid to me:


Assuming this is a leak, is that a clutch out job?

 

[mrcheesbrough]

Thanks for that, looks like fluid to me:
View attachment 12227

Assuming this is a leak, is that a clutch out job?

I'd be tempted to top it up for now and see if the problem returns. I'm assuming you've got a 102 or 150 TDI? Which from what I understand will require the removal of the gearbox to access it for replacement.

 

[J0Xd4E]

Yes, it's a 102 TDI. Silly question, is it just a case of buying brake fluid and topping up? Will it need bleeding or anything?

 

[mrcheesbrough]

Yes, it's a 102 TDI. Silly question, is it just a case of buying brake fluid and topping up? Will it need bleeding or anything?

Not too sure. I suspect that it may need bleeding through if it's completely out of fluid. Your garage may know the answer to that one - luckily to date I haven't needed to do this myself. Just a matter of time I imagine.

 

[rod_vw]

As far as I know the clutch slave cylinder is inside the gearbox bell housing on a 102ps. If it has leaked fluid then the clutch plate may well be contaminated. From what I know about these engine / gearbox setups you may be well advised to consider biting the bullet and having slave cylinder, clutch and dual mass flywheel all changed at the same time. The major labour involved with these jobs amounts to the same thing so doing it all in one go would probably be most cost effective.
However before you have a heart attack at the cost of the above you should check that there is no leakage from the clutch master cylinder (I think that would be inside the cab behind the pedals) as that could equally be the source of fluid loss / clutch operation failure.

Rod

 

[sidepod]

Isn't that a picture of a brake reservoir? Looks to me like the master cylinder is attached to the brake servo?

 

[mrcheesbrough]

Isn't that a picture of a brake reservoir? Looks to me like the master cylinder is attached to the brake servo?

It is the master cylinder, but the clutch has a slave cylinder in the gearbox. It uses the same reservoir as the brakes to keep topped up with fluid.

 

[mrcheesbrough]

Duh. Sorry. Fuzzy brain here. @sidepod - I you mean what I think it would be difficult to identify any leaks from the master cylinder from inside the footwell. And even then I think it would have to be quite a dramatic leak to show itself outside the brake servo.

 

[mrcheesbrough]

Gah! The fog is clearing. A bit more research done. The clutch master cylinder is in the footwell, mounted in the bulkhead, amongst the pedal assembly. A bit awkward to see, but possible as suggested by @rod_vw. It uses the brake master cylinder reservoir to supply it with fluid in the event of it losing any.

 

[J0Xd4E]

Thanks for all the info everyone, I've been recommended a garage that has enough headroom and have it booked in for Monday. In the meantime I'll be selling one of my children.

 

[rod_vw]

If you have problems finding a garage able to do the job I suggest that you try your nearest BT Fleet workshop. BT Fleet were contracted to maintain the AA fleet (and others) of T4 Transporters so should have all the necessary information to do the job.

Rod

 

[mrcheesbrough]

A

Thanks for all the info everyone, I've been recommended a garage that has enough headroom and have it booked in for Monday. In the meantime I'll be selling one of my children.

At least selling the children will make a little more space inside your camper.

 

[Rascal1]

Stick your foot UNDER clutch petal and pull pedal upwards.Be firm with it.Then see if it works...

 

[J0Xd4E]

I'd be tempted to top it up for now and see if the problem returns.

The new garage at least seems trustworthy as this is what they did, plus bleeding. After putting pressure on the clutch for a couple of hours couldn't find any evidence of a leak. They wondered if the previous place that fitted new brake pipes hadn't topped it up enough and allowed air in to the system. So I guess I'll keep an eye on the fluid and see what happens. Time to take the child off eBay for a bit at least.

 

[sidepod]

The new garage at least seems trustworthy as this is what they did, plus bleeding. After putting pressure on the clutch for a couple of hours couldn't find any evidence of a leak. They wondered if the previous place that fitted new brake pipes hadn't topped it up enough and allowed air in to the system. So I guess I'll keep an eye on the fluid and see what happens. Time to take the child off eBay for a bit at least.

Hmmm, don't be hasty. I'd leave it on, see how the bidding goes.

 

[mrcheesbrough]

The new garage at least seems trustworthy as this is what they did, plus bleeding. After putting pressure on the clutch for a couple of hours couldn't find any evidence of a leak. They wondered if the previous place that fitted new brake pipes hadn't topped it up enough and allowed air in to the system. So I guess I'll keep an eye on the fluid and see what happens. Time to take the child off eBay for a bit at least.

A promising result with your new garage. Always difficult to say exactly what the cause might be and you can never tell how thorough the previous owner/garage was when having work done. One of the joys of a pre-owned California.