I guess my clutch is kippered....

[Lankytim]

I'm having problems changing gear in my Audi, The pedal needs to be pushed through the carpet to get it into gear and even then its hard work, often crunching and making horrible noises. Basically its like the clutch isnt disengaging properly. The biting point is right at the floor too. Theres no adjustment left on the cable and theres no "backlash" on the clutch release arm, I.e the cable and clutch arm has no slack in it.

Ive had clutches go in many ways but this way seems to be a new one on me. Any advice?

Its a 1986 1.8 Audi 100 BTW!

[richy246]

Just had exactly the same thing with SWMBO Daewoo Nubira.I think the pressure plate fingers are just worn too much.Taking it all apart tomorrow to change the clutch ( thats if I can "pop" the driveshafts they are being a right pig at the mo )Will let you know the outcome.

[davej]

Check the clutch release arm isnt cracked. I was given a mk2 Passat 1.8 with a dead clutch, turned out the arm on the gearbox the cable operated was cracked so wasnt moving enough to engage gears. I overlooked it at first so was very happy to find a free fix! Not sure if its the same set up on your Audi but its worth a closer look!

[Lankytim]

Thanks chaps, the setup is the same as a MK2 Passat I believe so its worth checking out. There seems to be a bolt that attatches the arm to the clutch yoke inside the gearbox so maybe theres an element of adjustment that can be made.

[dubzi]

I had a similar problem on my Golf.
Turned out that there was only 1 bolt left holding the bellhousing to the engine and that was loose! Each time I pushed the clutch in the bellhousing was being pushed away from the engine. Seems the previous owner must have had some bolts left over when he changed the engine......

Also a common Golf problem is that the bulkhead cracks where the clutch cable goes through it. That means the cable pulls through when you press the pedal. Might be worth checking too.

[mrj]

WHS about the bulkhead , this is how it looks :




the Audi 90s have a reinforcement panel, that is bolted to the pedal box... if that has happened, i'd check the clutch cable, as a heavy clutch is mostly the reason for the cracked bulkhead...

[trackclassicsports]

Not sure about the older ones but ive lost count of the amount of A4 and A6's ive had in with pressure plates that have cracked and split into 2 pieces. You essentially only get half a release when this happens and usually displays similar symptons to what you are saying.
Basic test though, if you can get it into gear without the engine running then its the clutch. If its a sod without it running aswell then its gearbox.

[Lankytim]

Right, Only just had time to have a proper look. The good news is ive found the problem and its not the clutch, unfortunately the good news stops there.

I started by adjusting out all the pedal travel by removing the clutch release arm from its splined shaft in the gearbox and resetting it in a better position. Initially it looked like the arm had slipped on the splined shaft so I was hoping that it would cure the problem. I depressed the clutch pedal and it went to the floor. I then thought that the cable had stretched to excess and fitted a brand new one. All the travel and slack was adjusted out... would it work? There was no reason why not!

No it didnt.

The pedal went to the floor with the sensation of stepping on a partially decomposed cat, and stayed there. I pulled it back up with my hand and with a funny "splunk" noise it dangled lifelessly from the pedal box.

Further investigation revealed that the cross shaft thing inside the pedal box that takes the movement of the clutch pedal and transfers it across the pedal box to the actuating arm had slowly twisted and snapped. The end is splined and thats where its broken. So basically I need a new shaft but the pedal box needs to come out. I hear that pedal box removal isnt exactly a picnic though.

Ive just got the Audi back from the garage after having over £500 worth of work done, new brakes, brake lines, wheel bearings, bit of bodywork e.t.c and was going to go on holiday with the wife to Barmouth on Tuesday, weve now been reduced to going in an Austin Allegro.

I'm beginning to think this car is occupied by an evil spirit and is jinxed. Anyone know of a good priest?

Oh and I need a clutch pedal and shaft. I may try audi as a secondhand one may just break again.