2006 Jetta "Guess that clutch problem"

[kallisti5]

So, everything started failing at once a month or two ago.. I'm down to a hand full of issues now.

I recently had my clutch + flywheel replaced due to some slippage, clacking from transmission, and clutch pedal pressure issues. All of the symptoms disappeared after the clutch job except for the pedal pressure issues.

* Clutch operates normally until it warms up, then one of the following issues start:
- Slow decrease in clutch 'catch' point. (almost to the floor sometimes)
- random clutch 'stick' clutch sticks down, pop it back up with my foot things return to normal.


given the latter symptom, I'm thinking the clutch master cylinder under the dash is acting up. Thoughts?

I've actually never changed the hydraulic fluid (2-3 years). Think changing it would be a good start? (or just make things worse?)

Is there a bleeder valve on the clutch master cylinder under the dash? (know there is one on the slave under the air box)

 

[kallisti5]

now that I think about it, ignore my bleeder valve question... the slave would be the "end of the line" so there wouldn't be a bleeder valve on the master

 

[kallisti5]

Ah.. Think I fixed it.

Filled brake fluid to very, very, top.

After lots of sucking on the clutch (transmission side) bleeder and pumping on the clutch pedal I started get brown fluid followed by white foam out of the clutch hydraulics. I pretty much kept the reservoir full, and continuous suction on the bleeder and am pretty sure I got all the air out. (it finally started to run clear and run out *really* quick). Had a hell of a time getting the fluid moving when I first started.

Pedal feels much better now and is at the original height. I ran out of daylight but plan to do the brakes as well.. this fluid may have over a 100k miles on it (I have no idea what the owner before me did with maintenance)

 

[dieselfuel]

Thanks for posting your findings.

Nothing worse than asking for answers to a problem, fixing it and never letting the forum know what the fix was. People can't learn anything that way.

Please keep us informed.


df

 

[kallisti5]

Thanks for posting your findings.
Nothing worse than asking for answers to a problem, fixing it and never letting the forum know what the fix was. People can't learn anything that way.

Please keep us informed.
df

Haha, yeah I know it isn't the most interesting dribble... until you are facing it head on.

I'm guessing the air got into the hydraulics due to a leaking cylinder or something. I'll put some mileage on the clutch and suck some more fluid through looking for more bubbles to verify.

I may even post a quick video on youtube running new fluid through the hydraulics when I do it again... I'm noticing a pattern of Clutch flywheels coming apart, Hydraulics, and EGR leaks on the forums

 

[kallisti5]

Haha, yeah I know it isn't the most interesting dribble... until you are facing it head on.

I'm guessing the air got into the hydraulics due to a leaking cylinder or something. I'll put some mileage on the clutch and suck some more fluid through looking for more bubbles to verify.

Clutch began to fail after a few miles, I pulled the clutch slave, at first it just looked oily, but I tipped it on its side and hydraulic fluid ran out. Looks like it failed after 110k miles. Does everything start failing at 100k on these jettas?

 

[skthom]

Yes.

I just replaced my clutch slave cylinder as well. I'm at 122K.

 

[kallisti5]

What a pain... "small" issue.

While putting the new slave in, I knocked off the white friction tip on the rod (the tip that pushes the lever hooked to the throw out bearing.

Guess where that white tip went? Yup, right into the bell housing. I really don't want to pull the transmission for such a silly thing.

I'm thinking compressed air to see if I can blow it out somehow, or cracking open the bell housing to see it I can get it.

1) anyone think the small white chunk of plastic will damage my new SMF clutch?
2) I'm guessing i'll need a new slave as without that plastic friction material the throw out bearing arm will wear quite fast.

 

[Ski in NC]

My guess is that the plastic tip will either sit inert in the bottom of fw housing, or if it doesn't, it will get munched to dust with no harm to machinery. That still leaves you with the problem of finding another tip. I would not run it without the tip. It will chew up the contact point.

 

[kallisti5]

I "rented" a borescope from home depot and a long metal-springy claw grabber... too bad the bell housing is so tight and I can't get the borescope in to the bottom of the housing.

Oh well, just purchasing a second slave cylinder and hoping for the best. To be honest, i'm a little reluctant to use this same febi replacement slave given how easy the tip came off... I don't need *two* pieces of teflon / plastic in my bell housing

 

[VAsunshine]

2006 Mystery Clutch problem

Last November my 2006 VW TDI Jetta clutch went to the floor, replaced the slave clutch cylinder, the mechanic checked out the master cylinder, there was no leakage and he assumed was working properly. I picked the car up but clutch petal was different. Before the problem it would engage at the top of travel, now it was engaging closer to the floor. Less than 100 miles and I had the same problem, no clutch. Worked the petal by hand, no resistance. Had no fluids in floor of car, no change in fluid reservoir. The car was hauled back to mechanic, and he called and said the clutch was working. He drove for several days and parked. The "mystery" problem was back. The mechanic replaced the master cylinder and checked the line between the master and slave cylinders. The car/clutch has been working flawlessly since the last change.

My husband requested the master cylinder from the mechanic, he cut open the cylinder and found numerous white plastic chips and a white plastic disc floating and obviously blocking the line to the slave cylinder.

 

[spjackson1]

Many thanks to this thread and site. My son experienced the same clutch pedal stuck to the floor on his 06 Jetta TDI (130k miles). We replaced the slave cylinder, master cylinder, and the line that connects them. We also bled the whole brake and clutch system and all is back to top working order. All in all $250 in parts and 4-5 hours of time. Couldn't have done it without tips and pointers on this site.

 

[Boondoggle]

My clutch pedal on my 2007 Jetta went all the way to the floor and stayed there, I replaced the slave cylinder, and when I was bleeding it, something snapped inside by the pedal and this spring fell out
2006 Jetta clutch spring pedal assembly (having problems posting a picture)
Does anyone have a exploded drawing showing where this goes?