Technical Strange clutch problems

Currently reading:
Technical Strange clutch problems

Homebrewvan

New member
Joined
Feb 3, 2015
Messages
4
Points
1
I have 2003 2.8jtd Ducato, I've just rebuilt the gear box (the dreaded Syncro spring clips had fallen to bits ) gear change is like new, (we put a new beck and Borg clutch in when we put it together ) although I am having some strange clutch issues too, after a decent run ( a couple of hours on the motorway) the clutch becomes heavy, won't return fully up and the biting point is on the floor, making selecting first and second gear hard. After leaving her parked up over night, I pumped the clutch and it was fine, drove home no problem. Then did a series of short journeys , clutch was fine and felt great. At the weekend I drove to wales, same again when I arrived at the destination, although if I pull the clutch up after each gear it seems to help, again I pumped the clutch with the engine off in the morning and drove home with no issues at all.

Thanks for any advice .
 
Hi. Not too familiar with the Ducato is it a hydraulicclutch or cable?
 
Why did you wait until the following morning to pump it up?

If the clutch pedal is near the floor and there is air in then you should be able to pump it up straight away. For example select neutral then pump the clutch pedal several times. If it comes up again then there is probably air in it.

If it fails only when it is very hot after a long run then perhaps you have a problem with the fluid over heating?

In which case you may need to replace the clutch fluid with fresh.
[Although this does seem a less likely reason - just thinking what might be different after a long run.]

To confirm: after a long run the pedal is almost to the floor; in the morning it is still almost to the floor but comes up again after you pump it?
 
Hi. As I said not to familiar with this vehicle, if it has aflexi hose to the slave cylinder check it hasn’t been twisted on refit.
 
Hi guys, sorry, there's no notifications if anyone gets back. Yes, will try a bleed and also a look @ the fluid, got bigger problems ATM, I though there was a rattle at certain revs, on closer inspection, the bottom tensioner on the cambelt had no nut on it. The one through the plastic casing. Luckily I found out before any damage had occurred. I now want an exploded diagram so I can see the nut/washer position to see if I'm missing anything !
 
littlegraycat
No just after a run, the clutch pedal doesn't return fully to it highest point. After pulling it up with foot seems fine. And to also confuse matters , it was fine on 5 hour return Journey from North Wales !
 
Pedal not returning could be something jamming it or sticking pivot bush or weak return spring. Maybe get down and look with a good torch while moving the pedal slowly.

"Heavy" does suggest twisted - or partially blocked - hose though. Seen one on a Mini that had something other than hydraulic fluid used that had made the hose swell shut inside - had to really stand on the pedal.
 
Hi. If you wasn’t having this problem before the gearbox rebuild then I would think something has been refitted incorrectly.
The reason I mentioned flexi is we had almost identical symptoms on an old Ford when one of the apprentices had refitted the slave with one full turn twist on the flexi.
The result was when the engine was cold everything worked fine once the engine was warmed up the flexi softened and with the twist almost closed the pipe shut, the clutch became very heavy and the pedal would not return because the fluid could not return.
Is it possible that the flexi was damaged or crushed during the gearbox job?
 
Last edited:
Back
Top