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Sam:
This pitch doesn't make any sense to me. First of all how could it get rusty in there? Second, if it DID get wet, clutch friction disk might get stuck to flywheel, but would pop free instantly with engine pressure.
There's no way that pressure plate could be stuck in any way by rust that would make it stiff. It could be jammed by busting up or by some foreign object I suppose and that's what you'll find out when you take it all apart.
You asked earlier how to do this and I sort of ignored the post. Buy a Bentley manual for your car if you don't have one already, and read lots of posts on this site by using the Search box and typing in various key words about clutches, and you'll know how to go forward.
If it's a turbo you have ducts etc. to remove, as well as the annoying black plastic clutch cover.
IF the pressure plate is okay and not jammed you can remove it using the tips on here about how to remove a clutch without working hydraulics - - type "3 fat nuts" into the search box say.
If pressure plate is broken or jammed by something, that probably won't work and you might have to resort to the drastic method some seem to prefer, Sawzalling right through the slave cylinder, thus destroying it.
It seems hard for me to believe, even with something jammed, that someone could push down hard enough on the slave cylinder to "blow" its seals, especially a new slave cylinder, as they are o-rings held closely in machined grooves, pressing against the sides of a sliding cylinder, with no where to be "blown" to.
My guess is that the slave didn't get screwed down fully against the transmission. Three screws hold it, originally allen-head cap screws that are very hard to get a tool into and to make turn. Some say you can replace them with stock M-6 (6mm thread) metric hex head bolts.
If not all of those bolts were in and tightened down, the back of the slave cylinder wants to push out when you step on the clutch pedal. It only needs to move a little to let the o-ring seal to the case stop sealing and leak all the fluid out the back.
If that's what happened the 3 fat nuts method will let you get it all apart. You'll need a spacer tool (bucket handle, brake cable housing, 6 gauge copper wire, copper tubing, whatever) to hold pressure plate depressed. Also if slave just pushed apart, your parts are probably all fine; clean slave cylinder up, make sure no grime is inside (wash with rubbing alcohol and air dry it), push it all back together properly, and follow the Bentley book on reassembly.
Tell us what you find when you get in there.
posted by 71.241.193...
, Thu, 16 Aug 2007 08:28:27
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