A friend had replaced his clutch master cylinder and clutch slave cylinder. 2004 1.9 jtd.
Following the work selecting any gear very difficult. Baulking into all forward gears grinding trying to select reverse.
Lots and lots of bleeding bleeding from both bleed points , still the same.
I then bled it through at LOW pressure using Gibson easeee bleed.
Harrah, gear selection possible but... Bite point very very close to floor.
Never mind I say at least you can drive it again , see how you get on.
It didn't go well , about 100 miles later the gear selection problems were back.
The above happened about two weeks ago.
Got to look at it again today and will give the short version.
Measured master cylinder push rod movement from pedal up to pedal fully down it was around 21mm(remember this is a brand new part)
Measured the push rod movement of old master cylinder , result 33mm. Measured on my multipla 33mm.
Ok so found a big problem.
Pulled out new master cylinder piston , easy from inside drivers foot well,
Problem FOUND wrong return spring inside master cylinder. The spring coils were too close together and only allowing 21mm compression before closing up completely.
The faulty spring hadn't been finished properly at one end just cut off leaving a sharp point. It also looked like it has been exposed to the elements previously.
Conclusion not the spring it left the factory with!!!
Spring from old master cylinder fitted to car everything reassembled.
Ta da clutch works fine , all gears engage beautifully , bite point well up from floor (actually better than mine now grrr)
So if anyone else having similar gear engagement / bite point problems measure how far mc push rod travels into MC from pedal up to pedal fully down it should be about 33mm
If you buy a new MC check its travel before fitting or using the spring and piston.
Following the work selecting any gear very difficult. Baulking into all forward gears grinding trying to select reverse.
Lots and lots of bleeding bleeding from both bleed points , still the same.
I then bled it through at LOW pressure using Gibson easeee bleed.
Harrah, gear selection possible but... Bite point very very close to floor.
Never mind I say at least you can drive it again , see how you get on.
It didn't go well , about 100 miles later the gear selection problems were back.
The above happened about two weeks ago.
Got to look at it again today and will give the short version.
Measured master cylinder push rod movement from pedal up to pedal fully down it was around 21mm(remember this is a brand new part)
Measured the push rod movement of old master cylinder , result 33mm. Measured on my multipla 33mm.
Ok so found a big problem.
Pulled out new master cylinder piston , easy from inside drivers foot well,
Problem FOUND wrong return spring inside master cylinder. The spring coils were too close together and only allowing 21mm compression before closing up completely.
The faulty spring hadn't been finished properly at one end just cut off leaving a sharp point. It also looked like it has been exposed to the elements previously.
Conclusion not the spring it left the factory with!!!
Spring from old master cylinder fitted to car everything reassembled.
Ta da clutch works fine , all gears engage beautifully , bite point well up from floor (actually better than mine now grrr)
So if anyone else having similar gear engagement / bite point problems measure how far mc push rod travels into MC from pedal up to pedal fully down it should be about 33mm
If you buy a new MC check its travel before fitting or using the spring and piston.