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Old 03-20-2019, 11:48 PM
Frank Reiner Frank Reiner is offline
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Join Date: Feb 2011
Location: Modesto CA
Posts: 4,357
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Clutch problems can be separated into two areas: 1) Mechanical, & 2) Hydraulic

Faults of a mechanical nature arise in the pressure plate, the clutch disc, the release bearing, and the release lever.
After long use the diaphragm spring of the pressure plate can either take a permanent deflection, lose one or more fingers, or both.
In the clutch disc the lining can separate, the torsional damping springs in the hub can break, and the web between hub and lining can crack.
The release bearing may either seize, or the ball bearings wear out, leading to grinding & squealing noises.
The release lever may develop cracks which lead to excess flexing of the lever.

Hydraulic faults appear as leaks, and/or air in the system, as mis-adjustment of the clutch master cylinder (M/C) push rod, and as too short a M/C push rod being installed during replacement of the M/C.

The bottom-up bleeding method is the most dependable, particularly when done with a trigger type oil can. Although the RF caliper method is shown in the FSM, it is a bit hokey at best. A good quality oil can will pump without introducing air, and will displace fluid with sufficient velocity to sweep any air up thru the M/C and into the reservoir.
Once the system is clear of air, it is important to adjust the push rod eccentric to a maximum pedal clearance (free play) of 1/4". If there is too much free play the disengagement will occur, as described, close to the floor.
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