Low clutch pedal and occasional reverse gear grinding has been my issue so I finally checked clutch wear with my newly fabricated tool and found that there is still life in the clutch.
I pulled the slave to look for a leak but it was dry.
What else can cause these symptoms?
New clutch MC, fresh trans fluid have been done.
Would a worn throwout bearing cause it?

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

Possible answer:
* Air in the system = Low clutch pedal.
* Air in the system = difficulty disengaging the clutch = occasional gear grinding.

A very definite X2.

When I changed my master cylinder it took several attempts to get all the air out of it.

Watch out for the new plastic nipple in the MC as well its real brittle. mine cracked while driving and dumped the reservoir. Had to reuse the old one.

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Experience : what you receive 3 seconds after you really needed it !!



86 300SDL 387,000? Motor committed suicide
81 300SD 214,000 "new" 132,000 motor
83 300SD 212,000 parts car
83 300SD 147,000

91 F700 5.9 cummins 5spd eaton 298,000
66 AMC rambler American 2dr auto 108,000
95 Chevy 3/4 ton auto 160,000
03 Toyota 4runner 180,000 wifes

I agree, likely air still in the system. What was the pedal height before you changed the M/C?

__________________
80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

Since I did the MC [which was leaking] last year and I don't recall the exact pedal height but it was low. the system seemed to have bled ok but being the first time I had ever done such I had nothing to compare it to.

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1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

When I got mine I had to push it all the way to the floor. After the MC change out I think I push down 3 - 4" before engaging the clutch.

Make sure its adjusted so that fluid is returning to the reservoir . Theres a port that blocks fluid if the pedal is pressed slightly or adjusted to tight.

Chilton manual showed procedure. There's two adjustments . Overcenter spring and main rod.

__________________


Experience : what you receive 3 seconds after you really needed it !!



86 300SDL 387,000? Motor committed suicide
81 300SD 214,000 "new" 132,000 motor
83 300SD 212,000 parts car
83 300SD 147,000

91 F700 5.9 cummins 5spd eaton 298,000
66 AMC rambler American 2dr auto 108,000
95 Chevy 3/4 ton auto 160,000
03 Toyota 4runner 180,000 wifes

Well, since I already had the slave cylinder out I went ahead and installed the new one I had on the shelf so I won't have to do that again.
Then the RF wheel to slave bleed screw bleed procedure.
After all was said and done, I still have very low pedal engagement!
Soothappens; When I did the clutch MC r&r last year, I did not adjust the rod or spring. So you think that is a possibility?
If I remember correctly, while curled up under the dash, adjusting that puppy was a pita so that is why I may have neglected it.

__________________
1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

I did crawl under the dash today and fiddled with the clutch MC eccentric bolt, but no matter which way I moved it there was no real change in the clutch pedal freeplay. I did adjust the spring that is hooked to the clutch pedal to the manual spec but again no change in pedal engagement height.
The clutch begins engaging as soon as I start releasing the clutch pedal.
WTF!

__________________
1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

this is weird, is it possible its an internal leak in the new master? they don't need to be bench bled like a brake master, so it can't be that, it still has to be some kind of air issue!

Would be unlikely, but not necessarily that unusual if the master were the culprit, I had to replace one within 8 months of installation once on my sedan.

When you did the purge from the brake caliper, and you pumped the brake, were there any air bubbles still coming up out of the slave connection hose? I used a broken mirror taped to a linkage bar to watch for bubbles.

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This post brought to you by Carl's Jr.

I was doing the job alone so once the tube from the brake to the slave was full and hose clamped to the nipples, I had to open the bleeders, then push down the brake pedal and brace it while I closed the slave bleeder. Then I popped the brace and repeated the procedure.
I did this till the reservoir stopped dropping and needing top up.
I really never saw bubbles
I am using the ATE Blue fluid so it is very visible.
So , I suppose without eyeball proof there icould be air in the system.
I guess I need to get a helper and redo it.

__________________
1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

The eccentric bolt allows you to gain clearance between the rod and piston. The manual shows the spec. There is no freeplay adjustment . It sounds as if theres still air trapped in the system.

I had a hard time bleeding mine after replacing a slave cylinder . Bled it twice got in and the pedal hit the floor. I then pumped the pedal each time gaining more height . Its been about a month and I still have a good pedal. Usually It bleeds easy but there are several posts where its been a B**ch.

Good luck !!

__________________


Experience : what you receive 3 seconds after you really needed it !!



86 300SDL 387,000? Motor committed suicide
81 300SD 214,000 "new" 132,000 motor
83 300SD 212,000 parts car
83 300SD 147,000

91 F700 5.9 cummins 5spd eaton 298,000
66 AMC rambler American 2dr auto 108,000
95 Chevy 3/4 ton auto 160,000
03 Toyota 4runner 180,000 wifes

Thanks for the heads up on the eccentric, it did not seem to be an issue but I had to go through all the motions.
I will dig up a helper and do a rebleed and report back.

__________________
1981 240D 143k 4 spd manual -SOLD

2004 VW Jetta TDI 5 speed 300k -still driven daily

As you can see, not an easy task. It's too bad they can't make the whole system out of clear materials so we could see where the air is

There's a new post by Beagle describing an alternate method. Care to experiment with that?

Rick

__________________
80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

Another (unlikely) possibility is a bent clutch fork.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I had a weeping hose between master and slave that was sucking in air or letting enough fluid out. Worth checking especially if you have been moving it about when replaceing cylinders etc.

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